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[0001] This application claims Paris Convention priority of DE 10 2009 045 464.0 filed Oct. 7, 2009 the complete disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method for position dependent change in the magnetization in an object, according to a requirement, in a magnetic resonance experiment, wherein radio-frequency pulses are irradiated in conjunction with supplementary magnetic fields varying in space and over time that are superposed on the static and homogeneous basic field of a magnetic resonance measurement apparatus along a z-direction.
[0003] Such a method is known, for example, from reference [1].
[0004] Magnetic resonance imaging (MRI), also termed magnet resonance tomography (MRT), is a widespread technique for non-invasive acquisition of images of the interior of an object under examination based on the spatially resolved measurement of magnetic resonance signals from the object under examination. By exposing the object under examination to an essentially static and homogeneous magnetic basic field (also termed main magnetic field) within an examination volume of a magnetic resonance apparatus, nuclear spins contained in the object are aligned with the basic field, usually as the z-direction of a magnet-related coordinate system. The associated alignment of the magnetic dipole moments of the atomic nuclei results in magnetization within the object in the direction of the main magnetic field. This magnetization is referred to as longitudinal magnetization. In an MR examination (MR: magnetic resonance), a precessing motion of this magnetization is excited within the object under examination by irradiation of RF electromagnetic pulses (RF: radio frequency), whose frequency is proportional to the local magnetic field strength, by means of one or more RF transmission antennas. The vector of the magnetization is deflected from the equilibrium orientation (z-direction) through an angle hereinafter referred to as the flip angle.
[0005] In the MRI methods in general use today, spatial encoding is imposed on the precession movements of the nuclear spins for all three spatial directions by time-variable superposition of additional position-dependent magnetic fields, hereinafter referred to as supplementary magnetic fields. These supplementary magnetic fields usually exhibit essentially constant gradients of the z-component in the spatial directions x, y and z within the object under examination and are produced by a coil configuration, termed a gradient system, that is controlled by one gradient channel for each spatial direction. Where magnetic fields are described hereinafter as linear or non-linear, this refers, unless stated otherwise, to the spatial dependence of the z-component of the fields. The spatial encoding is usually described in a space, called k-space, that is conjugated to real space by means of a Fourier transformation. In this k-space formalism, which can only be applied to the use of magnetic fields with gradients that are constant in space, it is possible to describe the switching of supplementary magnetic field pulses as a progression along a trajectory in k-space, termed the k-space trajectory.
[0006] The transverse component of the precessing magnetization associated with the nuclear spins, hereinafter also referred to as the transverse magnetization, induces electrical voltage signals, which are also known as magnetic resonance signals (MR signals), in one or more RF reception antennas surrounding the object under examination. By means of pulse sequences that contain specially selected sequences of RF pulses and supplementary magnetic field pulses (brief application of supplementary magnetic fields that are constant or variable over time), time-variable magnetic resonance signals are produced in such a way that they can be converted to the corresponding spatial representations. This is done according to one of many well-known reconstruction methods after the MR signals have been acquired, amplified, and digitized using an electronic receiver system, processed using an electronic computer system, and stored in one-dimensional or mufti-dimensional data sets. The pulse sequence used typically contains a sequence of measurement operations (termed phase-encoding steps) in which the gradient pulses can be varied according to the chosen spatial encoding method.
[0007] The position dependent change in the magnetization, hereinafter abbreviated to SDMM (SDMM: spatially dependent modification of magnetization), is a widespread technique in magnetic resonance imaging that is used to convert magnetization that is present at one instant in an object under examination into new magnetization position-dependently by irradiating RF pulses in conjunction with supplementary magnetic fields that vary in space and over time. This means that, for each position within the object under examination, the magnetization present at that position is specifically modified or put into a condition that is defined specifically for this position. One example of this is the spatially selective excitation that is used to produce transverse magnetization within a specific space in an excitation volume and/or to vary its amplitude and phase spatially in accordance with defined distributions.
[0008] In slice selection, the most frequent case of spatially selective excitation, the excitation volume is reduced to a defined slice. The multi-dimensional, spatially selective excitation in which the excitation volume is restricted in more than one direction and/or the excitation is modulated in more than one direction, has also yielded numerous applications. These include excitation of a small three-dimensional volume within a much larger object under examination for localized spectroscopy, the mapping of a selectively excited region (ROI: region of interest) with a reduced field of view (FOV) with the aim of reducing the measurement time or improving resolution, the excitation of special volumes adapted to structures of the object under examination, or echo-planar imaging with reduced echo train lengths.
[0009] The amplitude and phase modulation of the transverse magnetization in the excitation can also be used to compensate for disadvantageous effects of a non-homogeneous magnetic transmission field (B 1 field) of the RF transmission antennas used for excitation. This is an application that has become considerably more important today due to the large increase in high field MRI systems on which such non-homogeneities especially occur. In addition to its use for excitation, the SDMM can also be used for spatially selective inversion or refocusing of the magnetization.
[0010] A further interesting application of SDMM is targeted production of a phase distribution of the transverse magnetization during excitation. In the method described in [15], a spatial phase pattern of the transverse magnetization of the nuclear spins is produced during excitation using three-dimensional selective excitation. This method at least partially compensates for dephasing of the MR signal due to susceptibility during the imaging experiment and thus reduces signal losses. This is achieved by calculating in advance the phase pattern used for phase compensation, that is, a spatial phase distribution of the transverse magnetization.
[0011] In the method disclosed in [16], such generation of phase patterns of the transverse magnetization during excitation is used to achieve partial or complete spatial encoding of the magnetic resonance signals during excitation. By repeated excitation with different phase patterns defined according to a phase encoding scheme and subsequent data acquisition on each repeat, a total data set is obtained from multiple phase encoding steps that is then reconstructed having been resolved spatially according the spatial encoding scheme and provides, for example, two- or three-dimensional images of the object under examination. This method for spatial encoding is hereinafter referred to as excitation encoding.
[0012] In the past, SDMM was initially performed using a single RF transmission antenna with an essentially homogeneous transmission field (B 1 field) in conjunction with the gradient system. Inspired by the success of parallel imaging in which signal acquisition with a configuration of multiple RF antennas (also termed an antenna array in the specialist literature) consisting of a plurality of individual antennas or elements, it has now become customary to also use such antenna arrays consisting of multiple elements operated on multiple, independent RF transmission channels of the MR measurement apparatus for transmission in SDMM. In this way, it is possible to partially replace the spatial encoding, which is implemented in SDMM by analogy with data acquisition, by varying supplementary magnetic fields, by so-called sensitivity encoding and thus to reduce the length of the excitation pulses. This enables use of the different spatial variations of the RF transmission fields of the individual array elements, hereinafter also referred to as transmission profiles.
[0013] Because, in the case of one-channel transmission, the length of selective excitation pulses is usually one of the criteria limiting the applicability of this technique, parallel excitation (PEX) or mufti-channel excitation is a promising approach by which spatially selective excitation may be deployed more widely than it has been. Spatial encoding during transmission of RF pulses for the purpose of selective excitation (hereinafter referred to as transmission spatial encoding) enables the amplitude and phase of the transverse magnetization produced during transmission to be set depending on the position. This transmission spatial encoding differs both from classic acquisition spatial encoding, which is performed without RF irradiation as part of data acquisition in a period following the excitation, in particular, during data acquisition, and also from the excitation encoding mentioned above, in which spatial encoding phase distribution of the transverse magnetization of the nuclear spins is already available after the excitation period.
[0014] One of the basic tasks when using SDMM is determination of the RF pulses to be replayed by the RF transmission system of the MR measurement apparatus to generate the required position-dependent change in the magnetization in conjunction with supplementary magnetic fields. In the article cited in the introduction “Designing Multichannel, Multidimensional, Arbitrary Flip Angle RF Pulses Using an Optimal Control Approach” (reference [1]), Xu et al. describe a method for multi-channel position-dependent change in the magnetization, by which the desired RF pulse shapes B 1,n (t) can be calculated for each of the I=1.n transmission channels based on the defined linear gradients of the k-space trajectory to be produced.
[0015] The calculation method of the RF pulses used for SDMM is generally based on the well-known Bloch equations for description of the development of the magnetization in an object during the influence of external magnetic fields. In [1], the pulse design problem based on the Bloch equations is expressed as an “optimal control” problem and the desired RF pulses are calculated by finding the solution to this problem.
[0016] As described above, in magnetic resonance imaging and in spatially resolved magnetic resonance spectroscopy, both during image acquisition and during SDMM, supplementary magnetic fields are usually used for spatial encoding that each have a spatially constant gradient in one spatial direction over the entire examination volume of the MR measurement apparatus. Because of this property of covering the entire examination volume, these supplementary magnetic fields are referred to as global gradients and the system component producing them as the global gradient system. Further, to simplify representation, it is assumed hereinafter that the basic field is oriented in the z-direction of a magnet-related coordinate system and that the gradients can be switched in three variants G x , G y and G z , whose z-components increase essentially linearly with settable strength in mutually orthogonal directions (see references [2],[3]).
[0017] Application of the strongest possible gradients, that is, the formation of the largest possible magnetic field difference between the edges of the examination volume, has substantial advantages which include implementation of very high position resolution. The fastest possible switching behavior for switch-on and switch-off of these gradients and setting of the gradient strength are also advantageous, for example, to shorten the total measurement procedure.
[0018] One disadvantage of the use of global gradients is that the gradient strengths required for typical applications correspond to considerable magnetic field differences between the edges of the mapping region. Their implementation reaches technical limits to the design of gradient coils and to the design of the gradient amplifiers in terms of size and switching behavior of the electric current to be generated by the gradient coils. Moreover, during rapid switching of these magnetic fields, rapidly changing Lorentz forces occur in the components of the MR measurement apparatus that can disadvantageously result in very large mechanical loads on the MR measurement apparatus and in excessive noise emission. A further limitation is imposed by neural stimulation of living objects under examination due to rapidly changing magnetic field strengths, so that in many cases, the image quality that would be technically possible cannot be achieved due to physiological restrictions with respect to acoustic load and nerve stimulation.
[0019] To avoid these limitations on global gradients, so-called local gradients were introduced for acquisition of magnetic resonance signals (see references [4],[5]). These are usually produced with a local gradient system that is included in the apparatus in addition to the global gradient system. The supplementary magnetic fields for spatial encoding are also produced with such a local gradient system. Unlike global gradients, in the case of local gradients, the z-component B Z (x,y,z) of each individual variant of the supplementary magnetic field is only either monotonically increasing or monotonically falling within each of one or more extensive and mutually contiguous partial regions of the examination volume along the gradient direction of the z-component (∂B z (x,y,z)/∂x, ∂B z (x,y,z)/∂y, ∂B z (x,y,z)/∂z). However, in the examination volume as a whole, there is no monotonic progression of B Z along this gradient direction. With one variant of such a local supplementary magnetic field, one-dimensional position determination along the stated gradient direction can be performed and components of the acquired magnetic resonance signals can be assigned to the individual iso-surfaces of the z-components B z (x,y,z) of the corresponding variant of the supplementary magnetic field. These iso-magnetic field surfaces are locally perpendicular to the gradient directions and must be known for spatial reconstruction from the magnetic resonance signals.
[0020] If position determination of the magnetic resonance signals is to be performed in multiple spatial dimensions, the corresponding number of suitable variants of the supplementary magnetic field, hereinafter referred to as F 1 , F 2 , . . . , are required. These can also be active simultaneously, depending on the encoding method. In the case of multi-dimensional spatial encoding using the local gradient system alone, unique spatial encoding is only possible in regions in which all variants of the supplementary magnetic field used for that purpose exhibit a monotonic dependence in the sense described above. These regions in which unique spatial encoding can be performed for all desired dimensions are hereinafter referred to as MSEM regions (MSEM=monotonic spatially encoding magnetic field).
[0021] The advantage to be gained from using such local gradients is that, within each of these MSEM regions, a spatially encoded magnetic field can be produced with a very steep rise and fast switching behavior. Among other purposes, this can be used to increase the spatial resolution in acquisition of magnetic resonance signals and/or to shorten the measurement operation. Because the magnetic field difference between the edges of an MSEM region and therefore also the magnetic field variation within the entire examination volume can be kept considerably smaller than in the case of global gradients, the disadvantages stated above of large, time-variable magnetic field variations within the nuclear resonance apparatus can be considerably reduced or avoided.
[0022] If magnetic resonance signals from the entire examination volume are spatially encoded using such a local gradient system, it is generally not possible, in the case of non spatially selective signal generation or acquisition, to make a spatial assignment of the MR signals based on the spatial encoding that is globally unique, that is, unique throughout the object under examination. In the case of a single MSEM region, it is not possible to ascertain which component of the signal originates from this region and which from outside. In the case of multiple MSEM regions, it is also generally not possible to distinguish which signal components originate from which MSEM region. In the case of a single MSEM region, this problem is usually solved by using excitation and/or reception antennas with restricted spatial sensitivity, in particular, so-called surface coils, so that only magnetic resonance signals within this MSEM region are excited and/or measured. In the case of local gradient systems that have multiple MSEM regions, unique assignment of the signal is achieved because unique assignment is possible using an antenna array with at least an equal number of suitably disposed reception elements of different sensitivity, as described in references [6] to [11]. This may necessitate a complex reconstruction method, for example, SENSE-like reconstruction (see reference [12]), (references [8] to [11]).
[0023] Unlike the developments described above in the field of acquisition of magnetic resonance signals, the position-dependent change in the magnetization SDMM according to prior art is still achieved with methods based on linear supplementary magnetic fields and is therefore also limited in its performance by technical and physiological constraints. These constraints limit the spatial resolution with which the change of magnetization can be performed, and/or require a certain minimum irradiation duration of the combination of RF pulses and supplementary magnetic fields to achieve the desired change in magnetization. The restriction of this spatial resolution and the delay caused by the minimum irradiation duration within the MR measurement sequence result in less favorable measurement conditions in many cases.
[0024] The object of this invention is therefore to provide a method for position dependent change in an object according to a requirement, in which this change in the magnetization is achieved with an at least locally spatially higher resolution and/or a shorter irradiation duration of the RF pulses and supplementary magnetic fields than is feasible according to prior art with linear supplementary magnetic fields produced by conventional gradient systems. In particular, this should be possible under the same technical and physiological conditions that currently constrain the performance of the methods using linear supplementary fields that are currently known in prior art.
SUMMARY OF THE INVENTION
[0025] This object is solved in a surprisingly simple but effective way in that non-linear supplementary magnetic fields are used, whose spatial gradient of the z-component is not constant at least at one instant during the irradiation, and that the radio-frequency pulses to be irradiated are calculated in advance, wherein progressions over time of the field strengths of the supplementary magnetic fields in the region of the object that are calculated and/or measured position-dependently are included in this calculation.
[0026] In the inventive method, for position dependent change in magnetization according to a requirement for this change, radio-frequency pulses are irradiated in conjunction with supplementary magnetic fields varying in space and over time that are superposed on the static and homogeneous basic field of the magnetic resonance measurement apparatus oriented in the z-direction in space. For this purpose, supplementary magnetic fields are used whose spatial gradient of the z-component is not constant, at least at one instant during the irradiation. The radio-frequency pulses can therefore not be calculated as in the previously disclosed methods that assume a linear spatial dependence of the supplementary magnetic fields so that their effect can be described by movement along a trajectory in k-space. In the inventive method, calculation of the radio-frequency pulses is performed based on position-dependently calculated and/or measured progressions over time of the supplementary magnetic fields in the region of the object.
[0027] It can be advantageous to use a combination of calculation and measurement in determining the position-dependent temporal dependences of the supplementary magnetic field strengths in the region of the object. For example, the contribution of a supplementary magnetic field that retains its spatial dependence during irradiation and only varies in its global amplitude can be determined by measuring the spatial dependence for a fixed amplitude in a separate preliminary experiment and scaling this measured dependence, to determine the spatial and temporal progression of the supplementary magnetic field, with the temporal progression of the amplitude defined by the sequence control unit of the magnetic resonance measurement apparatus. Such combined determination comprising calculation and measurement can, for example, be considerably more time-saving than completely measurement-based determination of the spatial and temporal progression of the supplementary magnetic field strengths.
[0028] Variants and further advantageous characteristics and embodiments of the invention are described below.
[0029] As part of the inventive method, unique transmission spatial encoding is also to be possible throughout the object.
[0030] In an especially preferred variant of the inventive method, supplementary magnetic fields are used that are such that, if a single RF transmission antenna is used whose transmission profile covers the entire object, at least one group of equivalent positions necessarily occurs within the object as part of SDMM. These are characterized by the fact that the change in the magnetization cannot be performed on them mutually independently, whatever the magnitude of position resolution. The simplest example of this is the fact that multiple positions exist in different regions of the object under examination at which the temporal field progression of the superposition of the supplementary magnetic fields is identical. In this case, an RF pulse that produces the same temporal RF field progressions at these positions as, for example, in irradiation with a spatially homogeneous transmission coil, would produce the same change in the magnetization so that only very special magnetization patterns whose symmetries correspond to those of the supplementary magnetic fields would be feasible. But even if the temporal field progression of the superposition of the supplementary magnetic fields at one position of such a group differs from those of another by, for example, an amount that is constant over time, the change in the magnetization at this position cannot be implemented independently of the other locations of the group.
[0031] To ensure that the change in the magnetization can nevertheless be performed at least at one position of a group independently of the other positions of the group, at least two RF transmission antennas are used that contribute to spatial encoding by their different transmission profiles in the region of the object. In this way, at least partial differentiation between equivalent positions in SDMM can be achieved.
[0032] In a further advantageous variant of the inventive method, the supplementary magnetic fields are such that the change in the magnetization can be performed with resolution varying over space. This is useful, for example, if the supplementary magnetic fields only permit a change in the magnetization with higher resolution at certain positions of the object that are of interest for the MR examination, while at less interesting positions only low resolution is possible, and if the supplementary magnetic fields have in total a lower maximum field strength than linear supplementary magnetic fields, which enable the higher resolution in the entire object. This lower maximum field strength can contribute to reducing the technical requirements of the gradient system producing the supplementary magnetic fields or to reducing the danger of peripheral nerve stimulation by supplementary magnetic fields that change excessively.
[0033] A very useful variant of the inventive method is to choose the setting of the position dependent change in the magnetization such that the inventive method causes a non-vanishing change in the magnetization only in one or more regions within the object. This can be used, for example, to produce transverse magnetization from the initial longitudinal magnetization only at certain positions as part of spatially selective excitation.
[0034] In this context, it can be advantageous to adapt the region(s) to anatomical, morphological or functional properties of the object under examination so that in this way, for example, certain regions of the object under examination that may interfere with the measurement are excluded from the excitation.
[0035] If a local gradient system is used for data acquisition that does not permit unique spatial encoding in the entire object, for example during spatially selective excitation only those region(s) can be excited whose union can be uniquely spatially encoded during data acquisition.
[0036] A further variant of the inventive method is particularly useful that is characterized in that the phase of the transverse magnetization is changed according to a defined spatial distribution. This can be advantageously used, for example, for pre-compensation of dephasing of the MR signal due to susceptibility during an imaging experiment and therefore for attenuation of signal losses by calculating the phase pattern used for phase compensation (that is, the spatial phase distribution of the transverse magnetization) in advance from the parameters of the imaging experiment.
[0037] This variant of the method can be further varied by performing the change in the spatial distribution of the phases of the transverse magnetization repeatedly in a magnetic resonance experiment in at least two so-called phase encoding periods in accordance with a spatial encoding scheme, by performing data acquisition after each of these phase encoding periods, and by reconstructing and storing and/or displaying as an image the totality of the data thus acquired having resolved it spatially according to the spatial encoding scheme. In this variant, the change in the phase patterns of the transverse magnetization is used to achieve partial or complete spatial encoding of the magnetic resonance signals during the change in magnetization. By repeated changes in multiple phase encoding periods with different phase patterns defined according to a phase encoding scheme and each followed by data acquisition, a total data set is obtained that is then reconstructed having been resolved spatially according to the spatial encoding scheme and, for example, provides two- or three-dimensional images of the object under examination. Further advantages of this variant are identical to the advantages described in [16] (e.g. direct acquisitions of FIDS, use of basically identical gradient pulses in all phase encoding periods, spatial variation of spatial resolution) because the method described in [16] essentially differs from this variant in that it is based on description of the supplementary magnetic fields as a k-space trajectory.
[0038] This variant is an example of how, with the inventive method, distributions of the amplitude and/or phase of the transverse magnetization can be produced that have a consistent pattern for the entire examination volume independently of the distribution of the examination volume in regions with different magnetic field progressions, for example, if the examination volume comprises multiple MSEMS. This variant enables, for example, spatial encoding of the MR signals to be performed for the entire examination volume or any mapping volume contained therein in such a way that image reconstruction is possible with a simple classic Fourier transform without having to take into account the special aspects of the non-linear supplementary magnetic fields in the reconstruction.
[0039] Conventional methods for position dependent change in the magnetization in an object under examination always require supplementary magnetic fields with a linear spatial dependence within the object, as is stated, for example, in [1], equations 1 and 7, by the representation of the supplementary magnetic field as the product G(t)·r=ΔB 0 (t,r), that is, the product of the gradient G(t), which is spatially constant because it is position independent, with the position coordinate r itself. In more specific conventional methods that are limited to spatially selective excitation in the small-angle regime (see [6] for example) this precondition is also necessary (see equation 1 ibid). The characteristic of the constant gradient is still used in this method to introduce the concept of the “transmission k-space” (see ibid. eqs. 7 and 8), which differs slightly from the usual reception k-space. For a defined temporal progression of the gradient, the transmission k-space coordinate is defined as
[0000]
k
(
t
)
=
-
γ
∫
t
T
t
′
G
(
t
′
)
,
(
1
)
[0000] wherein T denotes the total duration of the application of the supplementary magnetic fields and γ the gyromagnetic ratio of the examined nucleus. With this definition, it is possible to express the phase onto which the infinitesimal transverse magnetization produced at instant t is superposed by the supplementary magnetic fields while these fields are still being applied, as a function of the linear product k(t)·r and derive a design equation
[0000]
M
xy
(
r
)
=
i
γ
M
0
(
r
)
∫
0
T
t
B
1
(
t
)
exp
[
i
(
k
(
t
)
·
r
)
]
(
2
)
[0000] (see ibid. eq. 13). The conventional small-angle methods always work with design equations similar to equation (2) and therefore with the concept of the transmission k-space. However, this concept can only be defined for global constant gradients. The conventional pulse calculation methods are therefore unsuitable for a change in the magnetization using supplementary magnetic fields whose spatial gradient is not constant for at least one instant.
[0040] To circumvent this problem, it is conceivable to introduce a local k-space concept that is only valid for limited areas in the mapping area. However, the RF pulse calculation necessary for the inventive variant of the position dependent change in the magnetization is a more direct solution, as is expounded below.
[0041] First, an example is described of how the inventive pulse calculation can be performed for the range of small flip angles (<15°). According to the inventive method, the phase φ onto which the infinitesimal transverse magnetization produced at instant t is superposed (in the usual small-angle approximation) by the supplementary magnetic fields while these fields are still being applied follows explicitly from the general spatial and temporal progressions of the supplementary magnetic fields F j (t,r) as
[0000]
ϕ
(
t
,
r
)
=
-
γ
∫
t
T
t
′
∑
j
F
j
(
t
,
r
)
.
(
3
)
[0000] This results in the following design equation in the small-angle regime
[0000]
M
xy
(
r
)
=
i
γ
M
0
(
r
)
∫
0
T
t
∑
l
S
l
(
r
)
I
l
(
t
)
exp
[
-
i
γ
∫
t
T
t
′
∑
j
F
j
(
t
′
,
r
)
]
.
(
4
)
[0000] Here, SKr) are the transmission profiles of the RF transmission antenna associated with RF pulse shape I l (t). Further, r denotes the position variable; t, the time variable; M o (r), the position-dependent initial magnetization; y, the gyromagnetic ratio of the examined nucleus; T, the total duration of the longest RF pulse and the application of the supplementary magnetic fields; and M xy (r), the position-dependent transverse target magnetization. In this case, setting a target magnetization is equivalent to setting a position dependent change in the magnetization because the initial magnetization is defined.
[0042] The solution to the design equation (4) according to the RF pulse shapes I l (t) is obtained numerically by the generally known conjugate gradient method after discretization and conversion to a quadratic minimization problem.
[0043] This method for position dependent change, wherein the described RF pulses and supplementary magnetic fields are used, differs from an existing method for position dependent change in the magnetization using measured phase progressions φ(t,r) [13,14], in particular, in that the latter is based on experimentally measured phase dependences while this method is defined based on spatial and temporal progressions of the supplementary magnetic fields ΔB 0 (t,r), in particular, if these can be calculated as a product of statically measured or simulated spatial field progressions with defined temporal progressions according to
[0000]
Δ
B
0
(
t
,
r
)
=
∑
j
F
j
(
r
)
A
j
(
t
)
(
5
)
[0000] Now, one possible variant of the RF pulse calculation, required to apply the inventive method, for the range of any flip angles is described by way of example. For this purpose, a small-angle RF pulse is initially calculated, as described above, by suitably adapting the position-dependent target magnetization. The resulting RF pulse, that is, the totality of the RF pulse shapes for all RF transmission antennas, is now scaled with a factor that corresponds to the ratio between any desired flip angle of the magnetization and the postulated flip angle of the magnetization in the small-angle calculation (<15°). The scaled RF pulse is the starting point for the following iterative optimization by means of optimal control.
[0044] In this method, the Bloch equation is solved iteratively and, with each iteration, the RF pulse shapes are improved in that the combined application of the supplementary magnetic fields and the RF pulses causes a change in the position-dependent magnetization that approximates ever more closely to the defined target.
[0045] Integration of the Bloch equation for the magnetization at each position r
[0000]
(
M
.
x
(
t
,
r
)
M
.
y
(
t
,
r
)
M
.
z
(
t
,
r
)
)
=
γ
(
0
Δ
B
0
(
t
,
r
)
-
B
1
,
y
(
t
,
r
)
-
Δ
B
0
(
t
,
r
)
0
B
1
,
x
(
t
,
r
)
B
1
,
y
(
t
,
r
)
-
B
1
,
x
(
t
,
r
)
0
)
·
(
M
x
(
t
,
r
)
M
y
(
t
,
r
)
M
z
(
t
,
r
)
)
(
6
)
[0000] is performed based on the initial state of the magnetization for the total duration of the application of the supplementary magnetic fields and the RF pulses from t=0 to t=T. Here, B 1,x (t,r) and B 1,y (t,r) are the real and imaginary part of the transmission field. The progression of the supplementary magnetic fields as the product G(t)·r=ΔB 0 (t,r) from prior art is not suitable here. For this reason, according to the invention, the spatial and temporal dependences of the supplementary magnetic fields ΔB 0 (t,r) is directly included in the Bloch equation (6). In a variant of the inventive method, this dependence ΔB 0 (t,r) can be obtained from simulated and/or measured spatial supplementary field dependences and defined temporal progressions according to equation (5).
[0046] Integration of the Bloch equation yields the position dependent magnetization that theoretically results during application of the supplementary magnetic fields and the RF pulses of each iteration. In each iteration, this resulting magnetization is compared with the target magnetization that was defined by setting the change. Once the deviation falls below a defined, suitably chosen, magnitude, the iteration is terminated because the required RF pulse (the totality of the RF pulse shapes for all transmission antennas) has been found.
[0047] If the deviation λ i has not yet fulfilled the chosen criterion in the i-th iteration, the Bloch equation for λ(t,r) is integrated instead for the full position dependent magnetization, with an initial condition at instant T of λA(T,r)=A i . Integration therefore progresses from t=T to t=0. In this step, the Bloch equation is used with the inventive calculation of the supplementary magnetic fields.
[0048] According to the principles of calculus of variations, improved large-angle RF pulse shapes I l (t) opt are obtained from the calculated dependences M(t,r), λ(t,r) and I l (t) and the transmission profiles according to
[0000]
I
l
(
t
)
opt
=
I
l
(
t
)
-
μ
∑
r
λ
(
t
,
r
)
T
·
(
0
0
-
iS
l
*
(
r
)
0
0
S
l
*
(
r
)
iS
l
*
(
r
)
-
S
l
*
(
r
)
0
)
·
M
(
t
,
r
)
,
(
7
)
[0000] wherein a suitable increment μ is chosen. With the improved RF pulse shapes I l (t) opt , iteration is continued with forward integration of the Bloch equation.
[0049] In a variant of the inventive method, equivalent positions arise due to the use of non-linear supplementary magnetic fields that are characterized in that the magnetization as these two positions cannot be changed mutually independently based only on the progression of the supplementary magnetic fields and using one transmission antenna with a transmission profile covering the entire object, for example, if the progression of the superposition of the supplementary magnetic fields is identical. The inventive method permits, at least partially, independent change in the magnetization at these positions by using multiple transmission antennas with spatially different transmission profiles by the transmission of independent RF pulse shapes on these antennas and the therefore differing transmission fields at the equivalent positions.
[0050] Further advantages of the invention result from the description and the drawing. According to the invention, the characteristics stated above and further below can be used singly or in any combination. The embodiments shown and described are not intended to be an exhaustive list but are examples used to explain the invention.
[0051] The invention is represented in the figure and is explained in more detail with the help of an embodiment.
BRIEF DESCRIPTION OF THE DRAWING
[0052] The figures show:
[0053] FIG. 1 a schematic representation of an MR measurement apparatus according to prior art suitable for performing the inventive method;
[0054] FIG. 2 the spatial dependence of the z-component of two supplementary magnetic fields F 1 and F 2 in a cut plane of the object that is applied during transmission and whose gradients of the z-component are not constant. The amplitude of the fields is stated in relative units and is scaled as a function of time according to the amplitude weighting shown in FIG. 3 . The area shown is 6 cm×6 cm in size.
[0055] FIG. 3 the temporal progression A 1 and A 2 of the maximum amplitudes of the supplementary magnetic fields from FIG. 2 during application of the RF pulses. The spatial dependence of the supplementary magnetic fields is relative to this maximum amplitude, as shown in FIG. 2 .
[0056] FIG. 4 the target distribution of the x-component for the position-dependent change in the magnetization in a cut plane of the object. The spatial extent of the distribution shown is 6 cm×6 cm. The area shown in white corresponds to a required pure x-magnetization while the areas shown in black represent a required pure z-magnetization.
[0057] FIG. 5 two equivalent positions r 1 and r 2 , indicated by black crosses, are superposed on the supplementary magnetic field F 1 . An analogous image also results for F 2 . The black superposed outline of the position-dependent target magnetization illustrates that different magnetization is required at the two positions.
[0058] FIG. 6 the supplementary magnetic field strength ΔB 0 (t,r) at the equivalent positions r 1 and r 2 (see FIG. 5 ) as a function of time. To provide an overview, the supplementary magnetic field strengths are only shown as examples at the beginning and end of the application. Due to the central symmetry of the two supplementary magnetic fields F 1 and F 2 , the total dependence of the supplementary magnetic field strength is identical at both equivalent positions.
[0059] FIG. 7 the relative amplitudes of the spatial transmission profiles of the 8 transmission antennas that are included in the multi-channel pulse calculation. The pronounced spatial localization of the transmission profiles enables spatial differentiation between the equivalent positions that can be achieved, as in this example, with the use of non-linear supplementary magnetic fields.
[0060] FIG. 8 the result of simulation of the changed position dependent magnetization after application of the supplementary magnetic fields with non-constant gradients and only one transmission antenna with an homogeneous spatial transmission profile. As a result of the existence of equivalent positions, significant transverse magnetization has arisen at positions other than the positions defined by the target distribution (see FIG. 4 ). The magnitude of the transverse magnetization is smaller than required by the target distribution.
[0061] FIG. 9 the result of simulation of the changed position dependent magnetization according to the inventive method after application of the supplementary magnetic fields with non-constant gradients and RF pulses by eight transmission antennas with different spatial transmission profiles. Thanks to the use of multiple transmission antennas, the desired position-dependent magnetization can be achieved with sufficient precision.
[0062] FIG. 10 the target distribution of the x-component of the magnetization for evaluation of the resolution of the inventive method compared with the prior art. On the spatial extent of 6 cm×6 cm, points with alternating target magnetization are positioned at distances of 6/92 cm in each direction. White areas correspond to a required pure x-magnetization, while black areas represent a required pure z-magnetization.
[0063] FIG. 11 the result of simulation of the changed position dependent magnetization by an RF pulse according to prior art with eight transmission antennas and using conventional supplementary magnetic fields with constant gradients, whose progression has been chosen such that the resolution of the target distribution in FIG. 10 is not possible. This can be seen by the spatially relatively homogeneous magnetization.
[0064] FIG. 12 the result of simulation of the changed position dependent magnetization by an RF pulse according to the inventive method using the supplementary magnetic fields shown in FIG. 2 , whose maximum amplitude in the object matches the maximum amplitude of the conventional supplementary magnetic fields from the method according to prior art. It can be seen that, unlike FIG. 11 , the target magnetization can be achieved in the outer regions of the two-dimensional object and that the resolution varies spatially. The supplementary magnetic fields are used such that the change in the magnetization is performed with spatially varying spatial resolution.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0065] FIG. 1 schematically shows an MR measurement apparatus that is suitable for performing the inventive method. The system contains the main magnet M, with which the essentially homogeneous and static basic magnetic field is produced in a volume under examination V. The part of the object under examination that is contained in the volume under examination will subsequently be referred to as the object under examination or simply the object O. Surrounding this volume under examination V, a global gradient system, comprising three sets of gradient coils GX, GY, and GZ, and a local gradient system are put into the bore of the main magnet M with which different variants of local additional fields, local gradients, can be implemented by switching coils, usually multiple coils, to form coil combinations G 1 , G 2 . Global and local gradient systems do not have to be implemented as separate devices but may access shared gradient coils. FIG. 3 shows examples of 2 such coil combinations, G 1 and G 2 . In both gradient systems, additional magnetic fields with controllable duration and strengths can be superposed on the basic field. With gradient amplifiers AX, AY, AZ, A 1 , and A 2 that are controlled by a sequence control unit SEQ to produce gradient pulses at the right instant, the gradient coils sets GX, GY, GZ, G 1 , and G 2 are supplied with electric power to produce the additional fields.
[0066] Within the gradient field system, there are multiple transmission elements, TA 1 to TAn, that are together termed the transmission antenna equipment. They surround an object under examination O and are powered from multiple independent RF power transmitters TX 1 . . . TXn. The RF pulses produced by these RF power transmitters TX 1 . . . TXn are determined by the sequence control unit SEQ and triggered at the correct time. With the transmission elements TA 1 to TAn, RF pulses are irradiated onto the object under examination O in the volume under examination V, where they excite nuclear spins. The magnetic resonance signals caused by this are converted into electrical voltage signals with one or more RF reception elements RA 1 , . . . , RAm, but are then fed into a corresponding number of reception units RX 1 , . . . , RXm. The reception elements RA 1 , . . . , RAm are together termed the reception antenna equipment consisting of m reception elements RX 1 , . . . , RXm. They are also located within the gradient coils GX, GY, GZ, and surround the object under examination O.
[0067] To reduce the complexity of the apparatus, the transmission and reception antenna equipment can be designed and connected in such a way that one or more of the transmission elements TA 1 to TAn are also used to receive the magnetic resonance signals. In this case, which is not shown in FIG. 1 , switchover between transmission and reception modes is assured by one or more of the electronic transmission-reception switches controlled by the sequence control unit SEQ, that is, that during the RF transmission phases of the executed pulse sequence, this antenna or these antennas are connected with the corresponding RF power transmitter or transmitters and disconnected from the allocated reception channel or channels, while, for the reception phases, transmitter disconnection and reception channel connection is performed.
[0068] With the reception units RX 1 to RXm shown in FIG. 1 , the signals received are amplified and converted to digital signals using known signal processing methods and passed on to an electronic computer system COMP. In addition to reconstruction of images, spectra and derived quantities from the measured data received, the control computer system COMP is used to operate the entire MR measurement apparatus and to initiate execution of the pulse sequences by appropriate communication with the sequence control unit SEQ. User-guided or automatic execution of programs for adjusting the measurement apparatus characteristics and/or for generating magnetic resonance images is also performed by this control computer system COMP, as are visualization of the reconstructed images and storage and administration of the measurement and image data and control programs. For these tasks, this computer system is equipped with at least one processor, a working memory, a computer keyboard KB, a pointing device PNTR, for example, a computer mouse, a monitor MON, and an external digital storage unit DSK.
[0069] An explanation of how the inventive method can be performed with such an MR measurement apparatus is given below using a specific embodiment. The results shown were obtained by calculated simulation of an MR experiment in which a postulated position dependent initial magnetization is converted to a position dependent target magnetization in an object under examination by irradiation of RF pulses and the simultaneous effect of supplementary magnetic fields according to the inventive method.
[0070] According to the invention, at least two supplementary magnetic fields are used ( FIG. 2 ) that have a spatial gradient of the z-component that is not constant because the z-component depends non-linearly on position. The z-component of the superposition of these supplementary magnetic fields also has a non-constant gradient at all instants at which at least one of these supplementary fields is active.
[0071] As an example of the situation described in a dependent claim, two equivalent positions are shown. It is demonstrated below for this example that if one transmission antenna is used at these two positions, an identical, and therefore only mutually dependent change in the magnetization is performed and the desired position dependent change in the magnetization is only partially implemented. Moreover, it is demonstrated that when eight transmission antennas with different spatial transmission profiles are used, according to the inventive method, a different, mutually independent change in the magnetization at these two positions can be effected and the desired change in the magnetization can therefore be implemented at both positions.
[0072] FIG. 2 shows the spatial dependences of the two supplementary magnetic fields used F 1 and F 2 that can be produced with coils G 1 and G 2 of the local gradient system in FIG. 1 , while FIG. 3 shows the temporal progression of the amplitudes A 1 and A 2 of these fields during transmission of the RF pulses. By way of example, this therefore provides the basis for the calculation of the RF pulses according to the independent claim.
[0073] The initial situation for this embodiment is magnetization M(0,r) that is position dependent in two dimensions within the object under examination, wherein the magnetization is oriented in the z-direction at each position of the two-dimensional object on a grid of 96×96 points with the extent 6 cm×6 cm. The strength of this z-component corresponds to the value M z (0,r)=M 0 =)cos(0°)=1. The specific position-dependent change in the magnetization with the inventive method is to be effected in such a way that, due to the combined application of the supplementary magnetic fields and of the RF pulses, the x-component of the magnetization is given the distribution shown in FIG. 4 , also referred to as target distribution M T (r). Here, the areas shown in white correspond to a non-vanishing component M x of)sin(90°)=1 and the areas shown in black represent M x =0. The z-component of the magnetization is to be reduced to M Z =cos(90°)=0 in the white areas, while M y is to remain unchanged at zero everywhere.
[0074] An essential part of the inventive method is determination of the temporal progressions of the radio-frequency pulses to be irradiated. One possible procedure for this calculation is described below, for example, without going into varied alternatives and variations that are obvious to persons skilled in the art. First of all, to solve the Bloch equation iteratively below, a small-angle pulse is required as the starting point. The phase φ onto which the infinitesimal transverse magnetization produced at instant t is superposed by the supplementary magnetic fields while these fields are still being applied, is required for calculation of the small-angle pulse. This calculation is performed explicitly according to the inventive method from the known, in this case, electrodynannically calculated, spatial progressions of the supplementary magnetic fields F 1 and F 2 and the temporal progressions A 1 and A 2 defined by the sequence control of the MR measurement apparatus as
[0000]
ϕ
(
t
,
r
)
=
-
γ
∫
t
T
t
′
F
1
(
r
)
A
1
(
t
′
)
+
F
2
(
r
)
A
2
(
t
′
)
.
(
8
)
[0000] This results in the following design equation in the small-angle regime
[0000]
M
xy
(
r
)
=
i
γ
M
0
(
r
)
∫
0
T
t
∑
l
S
l
(
r
)
I
l
(
t
)
exp
[
-
i
γ
∫
t
T
t
′
F
1
(
r
)
A
1
(
t
′
)
+
F
2
(
r
)
A
2
(
t
′
)
]
.
(
9
)
[0000] Herein, S l (r) are the transmission profiles of the RF transmission antenna associated with RF pulse shape I l (t). FIG. 7 shows the relative amplitudes of the transmission profiles used. Further, r denotes the position variable; t, the time variable; M, the magnetization; γ, the gyromagnetic ratio of the proton; and T=83.1 ms, the total duration of the RF pulses and the application of the supplementary magnetic fields. The target magnetization distribution M xy (r) for the small-angle pulse design is derived from the target distribution described above (see also FIG. 4 ) that is set in the white areas M x =sin(10°=0.17. M y is unchanged at zero. In the small-angle pulse design, M z is also assumed to be constant over time.
[0075] The solution of the design equation (9) according to the eight RF pulse shapes I l (t) is obtained numerically after discretization and conversion into a quadratic minimization problem with the generally known conjugate gradient method.
[0076] The small-angle pulses obtained in this way (totality of the eight RF pulse shapes) is now scaled by a factor of 9, that is, with the ratio between the desired flip angle of the position dependent magnetization (here 90°) and the postulated flip angle of the position dependent magnetization in the small-angle calculation (here 10°). The scaled RF pulse is the starting point for the following iterative optimization by means of optimal control.
[0077] The following iteration steps are now repeated until the deviation λ(r) of the simulated position dependent magnetization of a particular iteration from the desired position dependent magnetization is sufficiently small (see step 2).
[0078] Step 1:
[0079] The transmission field B 1 (t,r) is calculated from the eight RF pulse shapes and the eight transmission profiles by
[0000]
B
1
(
t
,
r
)
=
∑
l
S
l
(
r
)
I
l
(
t
)
(
10
)
[0000] and the z-component of the supplementary magnetic fields of the progression of the superposition
[0000] Δ B 0 ( t,r )= F 1 ( r ) A 1 ( t )+ F 2 ( r ) A 2 ( t ) (11)
[0000] is calculated from the spatial and temporal progressions. With these functions, the Bloch equation
[0000]
(
M
.
x
(
t
,
r
)
M
.
y
(
t
,
r
)
M
.
z
(
t
,
r
)
)
=
γ
(
0
Δ
B
0
(
t
,
r
)
-
B
1
,
y
(
t
,
r
)
-
Δ
B
0
(
t
,
r
)
0
B
1
,
x
(
t
,
r
)
B
1
,
y
(
t
,
r
)
-
B
1
,
x
(
t
,
r
)
0
)
·
(
M
x
(
t
,
r
)
M
y
(
t
,
r
)
M
z
(
t
,
r
)
)
(
12
)
[0000] starting from the initial magnetization M(0,r) is numerically integrated forward in time at each position r until total duration T, with the result M(T,r). Here, B 1,x (t,r) and B 1,y (t,r) are the real and imaginary part of the transmission field and the dependence of M(t,r) is stored for each instant and position.
[0080] Step 2:
[0081] By calculating the vector difference between the position dependent magnetization obtained in step 1 and the target magnetization, the deviation
[0000] λ( r )= M ( T,r )− M T ( r ) (13)
[0000] is calculated. If the mean value of the squares of the absolute values of λ is less than 0.025 over all positions, that is, the mean square deviation is therefore below 2.5%, the iteration is terminated at this point and the eight pulse shapes of the current iteration are the result of the large-angle RF pulse calculation. Otherwise, the calculation moves onto step 3.
[0082] Step 3:
[0083] The Bloch equation for the vector deviation λ
[0000]
(
λ
.
x
(
t
,
r
)
λ
.
y
(
t
,
r
)
λ
.
z
(
t
,
r
)
)
=
γ
(
0
Δ
B
0
(
t
,
r
)
-
B
1
,
y
(
t
,
r
)
-
Δ
B
0
(
t
,
r
)
0
B
1
,
x
(
t
,
r
)
B
1
,
y
(
t
,
r
)
-
B
1
,
x
(
t
,
r
)
0
)
·
(
λ
x
(
t
,
r
)
λ
y
(
t
,
r
)
λ
z
(
t
,
r
)
)
(
14
)
[0000] is integrated backward in time using the transmission fields and the superposition of the supplementary magnetic fields from step 1 at each position r (i.e. λ=λ(T,r)) is the starting point for integration in negative time increments until t=0), and the dependence of λ(t,r) for each instant and position is stored. According to the known principles of calculus of variations which are the basis for optimal control methods, improved large-angle RF pulse shapes I l (t) opt are calculated from the transmission profiles and progressions of M(t,r), λ(t,r) and I l (t) by
[0000]
I
l
(
t
)
opt
=
I
l
(
t
)
-
μ
∑
r
λ
(
t
,
r
)
T
·
(
0
0
-
iS
l
*
(
r
)
0
0
S
l
*
(
r
)
iS
l
*
(
r
)
-
S
l
*
(
r
)
0
)
·
M
(
t
,
r
)
,
(
15
)
[0000] where an increment μ=2.5×10 −8 was chosen. With the improved RF pulse shapes I l (t) opt , the calculation now continues with step 1.
[0084] FIG. 8 shows the result of a simulation of the position dependent change in the magnetization according to a method that corresponds to the inventive method except for the number of transmission coils used. The result of using exactly one transmission coil with homogeneous transmission profile shows an unwanted multiplication of the target pattern because, if only one transmission coil is used, independent change in the magnetization is not possible at equivalent positions, such as r 1 and r 2 (see FIG. 5 ).
[0085] The result of a simulation of the position-dependently modified magnetization according to the inventive method is shown in FIG. 9 . Implementation of the target magnetization is enabled by the additional spatial selectivity of the eight transmission antennas used, TA 1 to TA 8 in FIG. 1 .
[0086] The characteristic of a non-constant gradient of the supplementary magnetic fields can also be advantageously used to effect the change in the magnetization, according to an dependent claim, with spatially varying resolution, as is illustrated in FIGS. 10 to 12 . The change in the magnetization is initially effected according to the inventive method as shown in the above example, with the difference that the position dependent target magnetization is replaced by the pattern shown in FIG. 10 . The result of simulation of position dependent magnetization modified in this way is shown in FIG. 12 . By comparison with this, FIG. 11 shows magnetization modified according to the prior art using linear supplementary magnetic fields, whose maximum amplitude in the object matches that from the inventive method. It can be seen that the spatial resolution in FIG. 12 varies in space and that the inventive method can implement the magnetization in the edge regions of the mapping area according to the resolution of the target magnetization, whereas the method according to prior art is unable to achieve this at any point.
LIST OF REFERENCE SYMBOLS
[0000]
A Array element
AX, AY, AZ, A 1 , A 2 Gradient amplifiers
COMP Computer system
DSK Storage unit
F 1 , F 2 Non-linear supplementary magnetic fields
GX, GY, GZ, G 1 , G 2 Gradient coils
G X , G y , G Z Gradients
KB Computer keyboard
M Main magnet
MON Monitor
Object under examination
PNTR Pointing device
RA 1 . . . m RF reception antennas
RX 1 . . . m Reception units
SEQ Sequence control unit
TA 1 . . . n RF transmission antennas
TX 1 . . . n RF power transmitter
V Examination volume
REFERENCES
[0000]
[1] Xu, D.; King, K. F.; Zhu, Y.; McKinnon, G. C.; Liang, Z. P.: Designing Multichannel, Multidimensional, Arbitrary Flip Angle RF Pulses Using an Optimal Control Approach , Magnetic Resonance in Medicine 59 (2008), 547-560.
[2] Bernstein, M. A.; King K. F.; Zhou, X. J.: Handbook of MRI Pulse Sequences . Elsevier Academic Press (2004).
[3] de Graaf, R. A.: In vivo NMR spectroscopy . John Wiley & Sons Ltd (1998).
[4] DE 10 2005 051 021 A1
[5] Hennig, J.; Welz, A. M.; Schultz, G.; Korvink, J.; Liu, Z.; Speck, O.; Zaitsev, M.: Parallel imaging in non - bijective, curvilinear magnetic field gradients: a concept study , Magn. Reson. Mater. Phy. 21 (2008), 544.
[6] Pauly, J.; Nishimura, D.; Macovski A.: A k - space analysis of small - tip - angle excitation , Journal of Magnetic Resonance 81 (1989), 43-56.
[7] Katscher U.; Börnert, P.; Leussler, C.; van den Brink, J. S.: Transmit SENSE , Magnetic Resonance in Medicine 49 (2003), 144-150.
[8] Meyer, C. H.; Pauly, J. M.; Macovski, A.; Nishimura, D. G.: Simultaneous spatial and spectral selective excitation , Magnetic Resonance in Medicine 15 (1990), 287-304.
[9] Setsompop, K.; Alagappan, V.; Gagoski, B.; Wald, L.; Adalsteinsson, E.: Uniform Wideband Slab Selection with B 1 +Mitigation at 7 T via Parallel Spectral - Spatial Excitation , Proceedings 16th Scientific Meeting, International Society for Magnetic Resonance in Medicine (2008), 616.
[10] Schomberg, H.; Bornert, P.: Off - resonance correction of nD spatially selective RF pulses , Proceedings 6th Scientific Meeting, International Society for Magnetic Resonance in Medicine (1998), 2059.
[11] Börnert, P.; Aldefeld, B.: On spatially selective RF excitation and its analogy with spiral MR image acquisition , Magnetic Resonance Materials in Physics, Biology and Medicine 7 (1998), 166-178.
[12] Pruessmann, K. P.; Weiger, M.; Scheidegger M. B.; Boesiger, P.: SENSE: Sensitivity Encoding for Fast MRI , Magnetic Resonance in Medicine 42 (1999), 952-962.
[13] Ullmann, P.; Haas, M.; Hennel, F.; Wick, M.; Voiron, J.; Zaitsev, M.; Hennig, J.; Ruhm, W.: Parallel Excitation Experiments Using Measured k - Space Trajectories for Pulse Calculation , Proceedings 16th Scientific Meeting, International Society for Magnetic Resonance in Medicine (2008), 1313.
[14] Unpublished patent application submitted to the German Patent and Trade Mark Office on 2009-04-01 with official application number 10 2009 002 112.4.
[15] Yip, C.; Fessler, J. A.; Noll, D. C.: Advanced Three - Dimensional Tailored RF Pulses for Signal Recovery in T* 2 - Weighted Functional Magnetic Resonance , Magnetic Resonance in Medicine 56 (2006), 1050-2059.
[16] DE 10 2007 044 463 B4 | A method for position dependent change in the magnetization in an object, according to a requirement in a magnetic resonance measurement, wherein radio-frequency pulses are irradiated in conjunction with supplementary magnetic fields that vary in space and over time and are superposed on the static and homogeneous basic field of a magnetic resonance measurement apparatus along a z-direction, is characterized in that non-linear supplementary magnetic fields are used, whose spatial gradient of the z-component is not constant at least at one instant of the irradiation, and that the radio-frequency pulses to be irradiated are calculated in advance, wherein progressions over time of the field strengths of the supplementary magnetic fields in the region of the object that are calculated and/or measured position-dependently are included in this calculation. This enables change in the magnetization with an at least locally spatially higher resolution and/or shorter irradiation duration of the RF pulses and supplementary magnetic fields than is feasible with linear supplementary magnetic fields produced by conventional gradient systems. In particular, this is possible under the technical and physiological conditions that currently constrain the performance of the known methods using linear supplementary fields. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Application Serial No. EP 08019311.3, filed on Nov. 5, 2008, and claims the benefit of U.S. Provisional Application Ser. No. 61/193,312, filed Nov. 11, 2008, the contents of which are incorporated herein by reference in their entirety.
FIELD
[0002] The disclosure relates to a finishing machine with stone turning unit.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Finishing machines with several finishing stones are used when the finishing process cannot be completed in one processing step, but prefinishing with a first finishing stone is carried out first and a still finer surface processing is carried out with a second finishing stone. Still further finishing stones may be provided, if necessary.
[0005] For these applications the finishing stones are known to be mounted on a stone turning unit and used one after the other to process a workpiece. A drive unit is required for the stone turning unit for this purpose, which serves to position the finishing stone required for the corresponding process in the respectively required position. Drive units are mounted on the stone turning unit in the finishing machines available on the market. A disadvantage of this concept is that this drive unit increases the mass and necessary installation space of the stone turning unit. The mass increase is even more significant when the stone turning unit as well as the finishing stone that is meshing with the workpiece have to perform an oscillating motion while the workpiece is being processed.
[0006] This is not only disadvantageous because of the increased drive power requirements, but also because of the need for increased guidance and bedding of the oscillating stone turning unit.
SUMMARY
[0007] We disclose a finishing machine available with a stone turning unit, which overcomes the disadvantages known from the state of the art and thus makes a more compact design possible with simultaneously reduced oscillating masses and drive power requirement. A finishing machine according to the principles disclosed herein may have at least two finishing stones, wherein the finishing stones are mounted on a stone turning unit, and wherein the stone turning unit positions one of the finishing stones in such a way that it may be made to mesh with the workpiece to be processed, wherein the workpiece or workpieces to be processed are clamped onto a workpiece holder, and wherein the workpiece holder may be driven by a controllable rotary drive, by coupling the stone turning unit to the rotary drive of the workpiece holder.
[0008] By the coupling, if necessary, the stone turning unit to the rotary drive of the workpiece holder, the rotary drive of the workpiece holder, which is provided in any case, may take over an additional function. This function may include turning, if necessary, the stone turning unit to such an extent that the respectively desired finishing stone is moved into processing position. Since exchanging the finishing stones by turning the stone turning unit is carried out only when the workpiece is not being processed, the rotary drive is not fully utilized anyway during this time interval and may take over the new function according to the principles of the disclosure without affecting the efficiency while the workpiece is being processed.
[0009] Another advantage may be seen in that the stone turning unit no longer requires a separate drive and is therefore designed smaller and lighter. The rotary drive used to drive the stone turning unit may not follow the movement of the finishing stone and the stone turning unit, so that the stone turning unit according to the disclosure is designed considerably lighter and consequently only causes lower mass forces when it is set into oscillating motion during processing. In this way, drive power is also saved, which may have an effect on the range of application and efficiency of the finishing machine.
[0010] In another variation of the disclosure, the stone turning unit is rotatably mounted and comprises a controllable clamping device. In this way, it is possible to couple the rotary drive of the workpiece holder to the stone turning unit when the clamping device is released during periods in which no workpiece is being processed and the stone turning unit may be rotated to such an extent by suitably controlling the rotary drive of the workpiece holder that the desired finishing stone reaches a processing position.
[0011] The stone turning unit is subsequently clamped again by controlling the controllable clamping device, so that the stone turning unit cannot be turned while the workpiece is being processed, and the desired finishing stone thus remains meshed with the workpiece to be processed.
[0012] A first switchable and controllable coupling according to the disclosure that is carried out between the rotary drive of the workpiece holder and the stone turning unit provides that the rotary drive comprises a first gear wheel, for example a first spur gear, the stone turning unit incorporates a second gear wheel, for example a second spur gear, and that the rotary drive and the stone turning unit are coupled in a way that the first gear wheel and the second gear wheel are caused to mesh with one another.
[0013] The angle of rotation, around which the stone turning unit is turned, may be directly determined by detecting the angle of the rotary drive of the workpiece holder and/or the workpiece holder by means of this rigid coupling. A rotary angle sensor of the workpiece holder can thus be used for positioning the stone turning unit. As an alternative, it is also possible to provide a separate rotary angle sensor in the stone turning unit, so that the position of the stone turning unit may be determined independently of the output signal of a rotary angle sensor of the rotary drive of the workpiece holder.
[0014] In another variation, the rotary drive and the stone turning unit may be coupled to one another by means of a jaw coupling.
[0015] It is also possible to produce a frictional wheel drive, if necessary, that is, a friction-locked coupling between the rotary drive and the stone turning unit. This may be carried out, for example, with a rubberized raceway on the rotary drive, which is pressed against a corresponding cylindrical surface of the stone turning unit.
[0016] If the stone turning unit has a separate rotary angle sensor, then a rigid coupling between the rotary drive and the stone turning unit may not be required. Any slip that occurs between the rotary drive and the stone turning unit may become irrelevant, since the control of the rotary drive of the workpiece holder is only interrupted when the stone turning unit has reached the desired position. This position is recorded clearly and with some accuracy via the own rotary angle sensor of the stone turning unit.
[0017] A process is also disclosed for exchanging a finishing stone that may be made to mesh with a workpiece to be processed, a finishing machine, wherein at least two finishing stones are mounted on a stone turning unit, wherein the workpiece or workpieces to be processed are clamped onto a workpiece holder and wherein the workpiece holder may be driven by a controllable rotary drive, and wherein the stone turning unit may be coupled to the rotary drive of the workpiece holder, by means of the following exemplary process steps:
[0018] Coupling the stone turning unit and the rotary drive, and activating the rotary drive of the workpiece holder, so that a second finishing stone takes the position of a first finishing stone.
[0019] This process has the advantages that were already mentioned in connection with the finishing machine according to the disclosed principles, so that reference is made to the descriptions made above in order to avoid repetitions.
[0020] In a further variation of the process according to the disclosed principles, processing of the workpiece or workpieces clamped on the workpiece holder is interrupted, while the stone turning unit is coupled to the rotary drive.
[0021] The finishing stones may be moved in this way into the desired position without touching the workpiece.
[0022] In order to prevent the stone turning unit from rotating relative to the workpiece during processing, the stone turning unit is fixed and/or gripped while the workpiece or workpieces are being processed.
[0023] The process, according to the disclosure, is easy to integrate into an already available numerical control of the machine tool and may also comprise more than two finishing stones. If the finishing process is carried out in three steps, a first finishing stone, a second finishing stone, and a third finishing stone for final processing are to be made to mesh with the workpiece to be processed, wherein the above mentioned process is respectively applied.
[0024] Further advantages and advantageous variations according to the disclosed principles are apparent from the following drawings, their description, and the patent claims. All features disclosed in the drawings, their description, and the patent claims can each be integrated into a variation of the disclosure individually or in any combination with one another.
[0025] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0026] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0027] FIG. 1 : a side view and top view of a first exemplary variation of a finishing machine according to the principles of the disclosure; and
[0028] FIG. 2 : a second exemplary variation of a finishing machine according to the principles of the disclosure.
[0029] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0031] FIG. 1 a shows a side view of a schematic representation of an exemplary variation of a finishing machine according to the disclosed principles, which has been reduced to its parts. The finishing machine has, for example, a workpiece holder 1 , onto which a workpiece 3 is clamped. The workpiece 3 is configured, for example, as a cylindrical ring, whose outer lateral surface is finely processed by superfinishing.
[0032] The workpiece holder 1 is coupled to a rotary drive 5 , which allows the rotation of the workpiece holder 1 and the workpiece 3 clamped thereon around an axis of rotation 7 . The rotary drive 5 is coupled via electric lines to a control device (not shown) of the finishing machine and is controlled according to the requirements of the finishing process. A rotary angle sensor, which is not shown, is integrated in the rotary drive 5 , and incorporated in the control of the finishing machine.
[0033] A first gear wheel in the shape of a spur gear 9 is torque-proof connected to the workpiece holder 1 at the lower end of the workpiece holder 1 in FIG. 1 a . The first spur gear 9 follows rotary motion of the workpiece holder 1 and/or of the rotary drive 5 . A stone turning unit 11 is illustrated on the right side of the workpiece 3 in FIG. 1 a . The stone turning unit 11 may be rotatably mounted in bearings 13 . The bearings 13 may be configured, for example, as deep groove ball bearings or tapered roller bearings.
[0034] In addition, the stone turning unit 11 has a controllable clamping device, which is not shown in FIG. 1 a . This clamping device may be configured, for example, in the shape of a shoe brake as a positive clamping device by means of a radially insertable and removable locking pin, which may be inserted into corresponding grooves and/or recesses (not shown) of the axis 15 of the stone turning unit 11 . A first finishing stone 17 and a second finishing stone 19 are arranged on the stone turning unit 11 below the bearing 13 . The arrangement of the finishing stones 17 and 19 can be better seen in the plan view according to FIG. 1 b.
[0035] From the plan view, according to FIG. 1 b , the second finishing stone 19 may be made to mesh with the workpiece 3 when the stone turning unit 11 is rotated 180°.
[0036] A second gear wheel, which is configured as a spur gear 21 , is arranged for this purpose in FIG. 1 a at the lower end of the stone turning unit 11 . The pitch diameter of the first gear wheel 9 and the second gear wheel 21 as well as the distance between the axis of rotation 7 of the rotary drive and the axis of rotation 23 of the stone turning unit 11 are adjusted in such a way relative to one another that the first gear wheel 9 and the second gear wheel 21 mesh with one another when the stone turning unit 11 is lowered in the direction of the Y axis until the first gear wheel 9 and the second gear wheel 21 are at the same height. Through the displacement and/or movement of the stone turning unit 11 in the direction of the negative Y axis relative to the rotary drive 1 and the workpiece 3 it is also ensured that the finishing stones 17 and 19 do not mesh with the surface of the workpiece 3 to be processed when the gear wheels 9 and 21 are meshed.
[0037] When the gear wheels 9 and 21 are meshed, the rotary drive 5 is driven in such a way that the stone turning unit 11 is rotated 180° in the exemplary variation shown in FIG. 1 , so that the first finishing stone 17 and the second finishing stone 19 interchange their positions relative to the workpiece 3 . The stone turning unit is subsequently again fixed with the clamping device, which is not shown, and is moved upward in the direction of the positive Y axis in FIG. 1 a until the second finishing stone 19 may be made to mesh with the surface of the workpiece 3 to be processed.
[0038] The movement of the second finishing stone 19 toward the workpiece 3 is then carried out by means of a corresponding movement of the stone turning unit in the direction of the negative X axis.
[0039] FIGS. 1 a and 1 b illustrate that the stone turning unit 11 according to the disclosed principles may be designed very simple, space-saving, and light. This may be advantageous in particular because the stone turning unit 11 and/or the finishing stone 17 or 19 , which meshes with the workpiece 3 , has to carry out, during processing a workpiece 3 , an oscillating motion in direction of the Y axis in order to produce the grinding pattern that is characteristic of superfinishing.
[0040] The lighter the stone turning unit is, the lower are the forces required for producing the desired oscillating motion of the stone turning unit 11 . At the same time, the mass forces are reduced, which likewise has a positive effect on the processing quality of the workpiece 3 .
[0041] Instead of the form-fitting coupling described in FIG. 1 between the rotary drive 5 and the stone turning unit 11 , also a force-fitting coupling, for example via a rubberized friction gear (not shown) is possible. A rotary angle sensor may be provided on the shaft 15 of the stone turning unit 11 , so that the exact position of the stone turning unit and/or of the finishing stones 17 and 19 may be detected by the machine control independently of the slip between the friction gear of the rotary drive 5 and the stone turning unit 11 .
[0042] FIG. 2 shows a further exemplary variation of a finishing stone according to principles disclosed. In this exemplary variation, the stone turning unit is arranged in the interior of the cylindrical workpiece 3 and is thus positioned in such a way relative to the rotary drive 5 that the axis of rotation 7 of the rotary drive 5 and the axis of rotation 20 of the stone turning unit run coaxially with respect to one another. The stone turning unit is then lowered in the direction of the negative Y axis in the direction of the rotary drive and/or of the workpiece holder 1 until a positive connection between the rotary drive 5 and/or the workpiece holder 1 and the stone turning unit 11 is generated. In the exemplary variation shown in FIGS. 2 a and 2 b , a radially arranged lug 23 , which interacts with a correspondingly shaped groove 25 at the lower end of the stone turning unit 11 in the manner of a claw coupling, is provided for this purpose in the workpiece holder 1 . In this case, it is also possible to create a force-fitting coupling by means of the friction surface instead of a positive coupling of the stone turning unit 11 and the rotary drive 5 .
[0043] After the stone turning unit 11 has been turned, it is again raised in the direction of the positive Y axis, so that the coupling between the rotary drive 5 and/or the workpiece holder 1 , on the one hand, and the stone turning unit 11 is canceled. One of the two finishing stones 17 , 19 is subsequently brought against the meshed surface of the workpiece 3 to be processed. After the coupling of the rotary drive 5 and the stone turning unit has been canceled, the stone turning unit is again clamped and/or locked. The desired finishing stone 17 or 19 is subsequently made to mesh with the surface of the workpiece 3 that is to be processed.
[0044] It should be noted that the disclosure is not limited to the variations described and illustrated as examples. A large variety of modifications have been described and more are possible from the disclosed principles. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of the protection of the disclosure and of the present patent. | A finishing machine with at least two finishing stones and a stone turning unit is proposed, in which the stone turning unit may be coupled to a rotary drive of the workpiece holder. A separate drive for the stone turning unit may thus be omitted, which results in a reduced weight of the stone turning unit and therefore lower drive power requirement of the stone turning unit and an improved processing quality. | 1 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/070,838, filed Mar. 26, 2008, and is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates to a user interface for alarm monitor management.
[0003] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
[0004] In the field of healthcare, caregivers (e.g., doctors and other healthcare professionals) often desire to monitor certain physiological characteristics of their patients. Accordingly, a wide variety of monitoring devices have been developed for monitoring many such physiological characteristics. These monitoring devices often provide doctors and other healthcare personnel with information that facilitates provision of the best possible healthcare for their patients. As a result, such monitoring devices have become a perennial feature of modern medicine.
[0005] One technique for monitoring physiological characteristics of a patient is commonly referred to as pulse oximetry, and the devices built based upon pulse oximetry techniques are commonly referred to as pulse oximeters. Pulse oximeters may be used to measure and monitor various blood flow characteristics of a patient. For example, a pulse oximeter may be utilized to monitor the blood oxygen saturation of hemoglobin in arterial blood, the volume of individual blood pulsations supplying the tissue, and/or the rate of blood pulsations corresponding to each heartbeat of a patient. In fact, the “pulse” in pulse oximetry refers to the time-varying amount of arterial blood in the tissue during each cardiac cycle.
[0006] Pulse oximeters typically utilize a non-invasive sensor that transmits light through a patient's tissue and that photoelectrically detects the absorption and/or scattering of the transmitted light in such tissue. A photo-plethysmographic waveform, which corresponds to the cyclic attenuation of optical energy through the patient's tissue, may be generated from the detected light. Additionally, one or more of the above physiological characteristics may be calculated based upon the amount of light absorbed or scattered. More specifically, the light passed through the tissue may be selected to be of one or more wavelengths that may be absorbed or scattered by the blood in an amount correlative to the amount of the blood constituent present in the blood. The amount of light absorbed and/or scattered may then be used to estimate the amount of blood constituent in the tissue using various algorithms.
[0007] In addition to monitoring a patient's physiological characteristics, a pulse oximeter or other patient monitor may alert a caregiver when certain physiological conditions are recognized. For example, a normal range for a particular physiological parameter of a patient may be defined by setting low and/or high threshold values for the physiological parameter, and an alarm may be generated by the monitor when a detected value of the physiological parameter is outside the normal range. When activated, the alarm may alert the caregiver to a problem associated with the physiological parameter being outside of the normal range. The alert may include, for example, an audible and/or visible alarm on the oximeter or an audible and/or visible alarm at a remote location, such as a nurse station. These patient monitors may generally be provided with default alarm thresholds. However, in some instances, it may be desirable to alter the thresholds for various reasons.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Advantages of the disclosure may become apparent upon reading the following detailed description and upon reference to the drawings in which:
[0009] FIG. 1 is a graph illustrating a patient's measured SpO 2 versus time in accordance with embodiments;
[0010] FIG. 2 is a perspective view of a pulse oximeter coupled to a multi-parameter patient monitor and a sensor in accordance with embodiments;
[0011] FIG. 3 is a block diagram of the pulse oximeter and sensor coupled to a patient in accordance with embodiments; and
[0012] FIGS. 4-8 are exemplary graphical user interfaces of the pulse oximeter in accordance with embodiments.
DETAILED DESCRIPTION
[0013] One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0014] Different patients may exhibit different normal ranges of physiological characteristic values. Factors such as age, weight, height diagnosis, and a patient's use of certain medications may affect the patient's normal ranges of physiological parameters. For example, with a neonate, the normal SpO 2 range may be 80-95 percent. In contrast, for a 40-year-old patient, the normal SpO 2 range may be 85-100 percent. Accordingly, it may be desirable to set different low and/or high thresholds for particular parameters based on the patient being monitored.
[0015] In addition, simply monitoring a patient's physiological parameters may result in excessive alarms if a parameter repeatedly exceeds a threshold only momentarily. Accordingly, an alarm integration method may be employed to reduce nuisance alarms on patient monitors. An exemplary alarm management system may be the SatSeconds™ alarm management technology available, for example, in the OxiMax® N-600x™ pulse oximeter available from Nellcor Puritan Bennett, LLC, or Covidien. Generally speaking, SatSeconds alarm management operates by integrating an area between an alarm threshold and a patient's measured physiological parameters over time. For example, a patient's SpO 2 readings may be charted, as in a graph 2 illustrated in FIG. 1 . The patient's SpO 2 readings may be displayed as a plot 3 in the graph 2 . Similarly, a threshold SpO 2 value (e.g., 85 or 90 percent) may be displayed as a line 4 in the graph 2 . Rather than sounding an alarm as soon as the patient's measured SpO 2 (plot 3 ) drops below the threshold value (line 4 ), the SatSeconds system measures an area 5 (shaded in FIG. 1 ) by integrating the difference between the plot 3 and the line 4 when the plot 3 is below the line 4 . The area 5 may be known as the SatSeconds value because it is a measure of saturation versus time. When the SatSeconds value exceeds a threshold value (e.g., a preset threshold or a user-input threshold), the caregiver may be alerted that the patient's oxygen saturation is too low. Due to the nature of this technology, a significant desaturation event 6 (e.g., a large drop in SpO 2 ) may cause the alarm to activate quickly because the SatSeconds threshold value may be exceeded in a short period of time 7 . In contrast, a minor desaturation event 8 (e.g., a drop in SpO 2 (line 4 ) to just below the threshold (line 6 )) may not cause the alarm to be activated quickly. That is, the minor desaturation event 8 may continue for a relatively long period of time 9 before the SatSeconds threshold value is exceeded. Exemplary SatSeconds threshold values may range from 0-200, where a threshold of 0 SatSeconds results in the alarm being activated as soon as the patient's measured SpO 2 (plot 3 ) drops below the threshold value (line 4 ).
[0016] Because the SatSeconds technology is relatively new in the medical field, it may be desirable to assist the caregiver in efficiently determining the desired SatSeconds threshold value. Accordingly, a patient monitoring system in accordance with embodiments of the present disclosure may include one or more user interfaces which enable the caregiver to change the SatSeconds threshold value and/or the SpO 2 threshold value. In addition, the user interfaces may include graphical representations, as described below, to assist the caregiver in determining the optimal thresholds for a patient. Although the techniques introduced above and discussed in detail below may be implemented for a variety of medical devices, the present disclosure will discuss the implementation of these techniques in a pulse oximetry system.
[0017] FIG. 2 is a perspective view of such a pulse oximetry system 10 in accordance with an embodiment. The system 10 includes a sensor 12 and a pulse oximetry monitor 14 . The sensor 12 includes an emitter 16 for emitting light at certain wavelengths into a patient's tissue and a detector 18 for detecting the light after it is reflected and/or absorbed by the patient's tissue. The monitor 14 may be configured to calculate physiological parameters received from the sensor 12 relating to light emission and detection. Further, the monitor 14 includes a display 20 configured to display the physiological parameters, other information about the system, and/or alarm indications. The monitor 14 also includes a speaker 22 to provide an audible alarm in the event that the patient's physiological parameters exceed a threshold. The sensor 12 is communicatively coupled to the monitor 14 via a cable 24 . However, in other embodiments a wireless transmission device (not shown) or the like may be utilized instead of or in addition to the cable 24 .
[0018] In the illustrated embodiment, the pulse oximetry system 10 also includes a multi-parameter patient monitor 26 . In addition to the monitor 14 , or alternatively, the multi-parameter patient monitor 26 may be configured to calculate physiological parameters and to provide a central display 28 for information from the monitor 14 and from other medical monitoring devices or systems (not shown). For example, the multi-parameter patient monitor 26 may be configured to display a patient's SpO 2 and pulse rate information from the monitor 14 and blood pressure from a blood pressure monitor (not shown) on the display 28 . Additionally, the multi-parameter patient monitor 26 may emit a visible or audible alarm via the display 28 or a speaker 30 , respectively, if the patient's physiological parameters are found to be outside of the normal range. The monitor 14 may be communicatively coupled to the multi-parameter patient monitor 26 via a cable 32 or 34 coupled to a sensor input port or a digital communications port, respectively. In addition, the monitor 14 and/or the multi-parameter patient monitor 26 may be connected to a network to enable the sharing of information with servers or other workstations (not shown).
[0019] FIG. 3 is a block diagram of the exemplary pulse oximetry system 10 of FIG. 1 coupled to a patient 40 in accordance with present embodiments. One such pulse oximeter that may be used in the implementation of the present technique is the OxiMax® N-600x™ available from Nellcor Puritan Bennett LLC, but the following discussion may be applied to other pulse oximeters and medical devices. Specifically, certain components of the sensor 12 and the monitor 14 are illustrated in FIG. 2 . The sensor 12 may include the emitter 16 , the detector 18 , and an encoder 42 . It should be noted that the emitter 16 may be configured to emit at least two wavelengths of light, e.g., RED and IR, into a patient's tissue 40 . Hence, the emitter 16 may include a RED LED 44 and an IR LED 46 for emitting light into the patient's tissue 40 at the wavelengths used to calculate the patient's physiological parameters. In certain embodiments, the RED wavelength may be between about 600 nm and about 700 nm, and the IR wavelength may be between about 800 nm and about 1000 nm. Alternative light sources may be used in other embodiments. For example, a single wide-spectrum light source may be used, and the detector 18 may be configured to detect light only at certain wavelengths. In another example, the detector 18 may detect a wide spectrum of wavelengths of light, and the monitor 14 may process only those wavelengths which are of interest. It should be understood that, as used herein, the term “light” may refer to one or more of ultrasound, radio, microwave, millimeter wave, infrared, visible, ultraviolet, gamma ray or X-ray electromagnetic radiation, and may also include any wavelength within the radio, microwave, infrared, visible, ultraviolet, or X-ray spectra, and that any suitable wavelength of light may be appropriate for use with the present techniques.
[0020] In one embodiment, the detector 18 may be configured to detect the intensity of light at the RED and IR wavelengths. In operation, light enters the detector 18 after passing through the patient's tissue 40 . The detector 18 may convert the intensity of the received light into an electrical signal. The light intensity may be directly related to the absorbance and/or reflectance of light in the tissue 40 . That is, when more light at a certain wavelength is absorbed or reflected, less light of that wavelength is typically received from the tissue by the detector 18 . After converting the received light to an electrical signal, the detector 18 may send the signal to the monitor 14 , where physiological parameters may be calculated based on the absorption of the RED and IR wavelengths in the patient's tissue 40 .
[0021] The encoder 42 may contain information about the sensor 12 , such as what type of sensor it is (e.g., whether the sensor is intended for placement on a forehead or digit) and the wavelengths of light emitted by the emitter 16 . This information may allow the monitor 14 to select appropriate algorithms and/or calibration coefficients for calculating the patient's physiological parameters. The encoder 42 may, for instance, be a coded resistor which stores values corresponding to the type of the sensor 12 and/or the wavelengths of light emitted by the emitter 16 . These coded values may be communicated to the monitor 14 , which determines how to calculate the patient's physiological parameters. In another embodiment the encoder 42 may be a memory on which one or more of the following information may be stored for communication to the monitor 14 : the type of the sensor 12 ; the wavelengths of light emitted by the emitter 16 ; and the proper calibration coefficients and/or algorithms to be used for calculating the patient's physiological parameters. Exemplary pulse oximetry sensors configured to cooperate with pulse oximetry monitors are the OxiMax® sensors available from Nellcor Puritan Bennett LLC.
[0022] Signals from the detector 18 and the encoder 42 may be transmitted to the monitor 14 . The monitor 14 generally may include processors 48 connected to an internal bus 50 . Also connected to the bus may be a read-only memory (ROM) 52 , a random access memory (RAM) 54 , user inputs 56 , the display 20 , or the speaker 22 . A time processing unit (TPU) 58 may provide timing control signals to a light drive circuitry 60 which controls when the emitter 16 is illuminated and the multiplexed timing for the RED LED 44 and the IR LED 46 . The TPU 58 control the gating-in of signals from detector 18 through an amplifier 62 and a switching circuit 64 . These signals may be sampled at the proper time, depending upon which light source is illuminated. The received signal from the detector 18 may be passed through an amplifier 66 , a low pass filter 68 , and an analog-to-digital converter 70 . The digital data may then be stored in a queued serial module (QSM) 72 for later downloading to the RAM 54 as the QSM 72 fills up. In one embodiment, there may be multiple separate parallel paths having the amplifier 66 , the filter 68 , and the A/D converter 70 for multiple light wavelengths or spectra received.
[0023] The processor(s) 48 may determine the patient's physiological parameters, such as SpO 2 and pulse rate, using various algorithms and/or look-up tables based on the value of the received signals corresponding to the light received by the detector 18 . Signals corresponding to information about the sensor 12 may be transmitted from the encoder 42 to a decoder 74 . The decoder 74 may translate these signals to enable the microprocessor to determine the proper method for calculating the patient's physiological parameters, for example, based on algorithms or look-up tables stored in the ROM 52 . In addition, or alternatively, the encoder 42 may contain the algorithms or look-up tables for calculating the patient's physiological parameters. The user inputs 56 may be used to change alarm thresholds for measured physiological parameters on the monitor 14 , as described below. In certain embodiments, the display 20 may exhibit a minimum SpO 2 threshold and a selection of SatSeconds values, which the user may change using the user inputs 56 . The monitor 14 may then provide an alarm when the patient's calculated SpO 2 integral exceeds the SatSeconds threshold.
[0024] FIG. 4 illustrates an exemplary monitor 14 for use in the system 10 ( FIG. 2 ). The monitor 14 may generally include the display 20 , the speaker 22 , the user inputs 56 , and a communication port 80 for coupling the sensor 12 ( FIG. 2 ) to the monitor 14 . The display 20 may generally show an SpO 2 value 82 (i.e., percentage), a pulse rate 84 (i.e., beats per minute), a plethysmographic waveform (i.e., a plot 86 ), and a graphical representation 88 of the measured SpO 2 value versus time (i.e., a plot 90 ). In addition to displaying a trend of the patient's SpO 2 value, the graph 88 may serve as an indicator of the SatSeconds value. For example, a set SpO 2 threshold value (i.e., a line 92 ) may be displayed on the graph 88 with the plot 90 . When the measured SpO 2 value (i.e., the plot 90 ) drops below the threshold value (i.e., the line 92 ), an area 94 between the plot 90 and the line 92 may begin to fill in on the display 14 . At this time, the monitor 14 may begin to integrate the difference between the measured SpO 2 value (i.e., the plot 90 ) and the threshold value (i.e., the line 92 ). When the area 94 reaches a set value (i.e., the SatSeconds threshold value), the monitor 14 may indicate to the caregiver that a desaturation event is occurring, for example, by sounding an alarm via the speaker 22 , displaying an alert message on the display 20 , sending a signal to a nurse's station, or otherwise providing a notification that the patient's physiological parameters are not normal.
[0025] The user inputs 56 may enable the caregiver to control the monitor 14 and change settings, such as the SpO 2 threshold value and/or the SatSeconds threshold value. For example, an alarm silence button 96 may enable the caregiver to silence an audible alarm (e.g., when the patient is being cared for), and volume buttons 98 may enable the caregiver to adjust the volume of the alarm and/or any other indicators emitted from the speaker 22 . In addition, soft keys 100 may correspond to variable functions, as displayed on the display 22 . The soft keys 100 may provide access to further data displays and/or setting displays, as described further below. Soft keys 100 provided on the display 20 may enable the caregiver to see and/or change alarm thresholds, view different trend data, change characteristics of the display 20 , turn a backlight on or off, or perform other functions.
[0026] As indicated, the caregiver may access an alarm threshold control display 110 , an embodiment of which is illustrated in FIG. 5 , by selecting the limits soft key 100 ( FIG. 4 ). The alarm threshold control display 110 may enable the caregiver to view and/or change both an SpO 2 threshold 112 and a SatSeconds threshold 114 . In addition, a graphical representation 116 of the effect of the SpO 2 threshold 112 and the SatSeconds threshold 114 may be provided. The graphical representation 116 may include, for example, an exemplary SpO 2 plot 118 and a line 120 corresponding to the SpO 2 threshold 112 . As will be illustrated further, the exemplary SpO 2 plot 118 may remain constant so that the caregiver can clearly see how changes to the SpO 2 threshold 112 and the SatSeconds threshold 114 will affect the alarm settings.
[0027] Based on the SpO 2 threshold 112 and the SatSeconds threshold 114 , an alarm indicator 122 may illustrate the time at which the alarm would be sounded in the SpO 2 plot 118 . That is, given the SpO 2 plot 118 and the thresholds 112 and 114 , the monitor 14 ( FIG. 2 ) would alert the caregiver to a problem at the point indicated by the alarm indicator 122 . A shaded symbol 124 may correspond to the SatSeconds threshold 114 to indicate to the caregiver the size of an area 126 between the threshold line 120 and the plot 118 which must be filled before the alarm would go off. Furthermore, the first area 126 which corresponds to the SatSeconds threshold 114 may be shaded in to enable the caregiver to see where the SatSeconds threshold 114 is first exceeded on the exemplary SpO 2 plot 118 . The shaded in area 126 may correspond to the alarm indicator 122 .
[0028] The thresholds 112 and 114 may be changed via soft keys. For example, an SpO 2 soft key 128 may be selected to change the SpO 2 threshold 112 , or a SatSeconds soft key 130 may be selected to change the SatSeconds threshold 114 . Selection of the threshold 112 or 114 may be indicated, for example, by a backlight, a color change, an underline, or any other indication method. The threshold 112 or 114 may then be changed by pressing increment soft keys 132 . The left increment soft key 132 may be pressed to decrease the threshold 112 or 114 , while the right increment soft key 132 increases the threshold 112 or 114 . It should be understood that the position of the increment soft keys 132 may be reversed. The increment soft keys 132 may be up and down arrows, left and right arrows, a minis sign and a plus sign, “UP” and “DOWN,” or any other indicator which enables the caregiver to clearly adjust the thresholds 112 and 114 . The thresholds 112 and 114 may be displayed as a numerical value 134 (e.g., the SpO 2 threshold 112 ), a virtual knob 136 (e.g., the SatSeconds threshold), or any other value indicator. In addition, the thresholds 112 and 114 may be adjusted in increments of any size. For example, the SpO 2 threshold 112 may be adjusted in increments of 1% while the SatSeconds threshold 114 may be adjusted in increments of 25. A number of discreet values may be available for the thresholds 112 and 114 , or the value adjustment may be continuous.
[0029] As described above, changes in the thresholds 112 and/or 114 are illustrated in the graphical representation 116 . While the SpO 2 plot 118 remains constant, the threshold line 120 may move up or down based on changes to the SpO 2 threshold. Furthermore, in the case of a color display 110 , the SpO 2 threshold value 112 and the line 120 may be the same color, which is different from the other colors in the graphical representation 116 . Similarly, the SatSeconds symbol 124 and the area 126 may change based on the SatSeconds threshold 114 . The SatSeconds threshold 114 , symbol 124 , and area 126 may be illustrated in the same color, which is different from the other colors on the display 110 . By color-coding the display 110 , the caregiver may further see how the threshold values 112 and 114 affect the alarm settings. In addition, the SatSeconds symbol 124 may take on various forms to further illustrate the differences in SatSeconds thresholds 114 . For example, the symbol 124 may be a square which varies in size based on the threshold 114 , or the symbol 124 may be a square of constant size which fills up based on the threshold 114 .
[0030] FIGS. 5-7 illustrate how changes in the SpO 2 threshold 112 and the SatSeconds threshold 114 are illustrated in the graphical representation 116 . For example, in FIG. 5 the SatSeconds threshold 114 is increased from 25 ( FIG. 4 ) to 100. The SpO 2 threshold 112 remains at 85%, unchanged from FIG. 4 . The alarm indicator 122 in FIG. 5 is moved over relative to the alarm indicator 122 in FIG. 4 because the SatSeconds threshold 114 is greater. In addition, two areas 126 in which the SpO 2 plot 118 drops below the SpO 2 threshold line 120 are not shaded in because the SatSeconds threshold 114 is not reached before the plot 118 again goes above the line 120 . The SatSeconds symbol 124 is illustrated as a larger square in FIG. 5 , corresponding to the high SatSeconds threshold 114 .
[0031] FIG. 6 illustrates the difference in alarm settings when the SpO 2 threshold 112 is increased from 85% ( FIG. 5 ) to 90% ( FIG. 6 ). The SatSeconds threshold 114 is constant from FIG. 5 to FIG. 6 . As the alarm indicator 122 and the area 126 illustrate, the SatSeconds threshold 114 is reached earlier in FIG. 6 than in FIG. 5 . Because the SpO 2 plot 118 does not go above the SpO 2 threshold line 120 after the first desaturation event, calculation of the SatSeconds value is not reset. Therefore, the alarm will be activated earlier for the given plot 118 .
[0032] Finally, FIG. 7 illustrates the effect that reducing the SatSeconds threshold 114 to zero will have on the alarm settings. At a threshold 114 of zero, the alarm will be activated as soon as the SpO 2 plot 118 falls below the threshold line 120 , as illustrated by the indicator 122 . There is no shaded area 126 because the SatSeconds integration, as described above, is not needed in this example.
[0033] While only certain features have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within their true spirit. | The present disclosure provides a system and method for facilitating user input of alarm settings for a patient monitor. In various embodiments, a pulse oximetry monitor may include a graphical user interface (GUI) which is capable of displaying a graph of blood oxygen saturation percentage over time. The system may be capable of allowing a user to enter an alarm threshold value and/or an alarm integration threshold value. The alarm threshold value may be displayed as a line on the graph, and the alarm integration threshold value may be displayed as a shaded area on the graph. The GUI may include an indicator of where an alarm would be initiated given the graph, the input alarm threshold value, and/or the alarm integration threshold value. The disclosed GUI may provide the user with a clear illustration of how the alarm threshold value and alarm integration threshold value may affect the alarm. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part to U.S. patent application Ser. No. 10/703,357 titled, “Dental Device,” filed 7 Nov. 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to dental devices.
BACKGROUND OF THE INVENTION
[0003] Teeth are covered with a sticky film of bacteria, called plaque. Within this film live thousands of different types of bacteria. Of all these many different types of bacteria, one causes tooth decay: that bacterium is called Strep Mutans.
[0004] After eating a meal, small crumbs of food are left in mouths. The Strep Mutans bacteria eat these crumbs and produce harmful acid. This acid can attack tooth enamel for as long as 20 minutes or more. Repeated acid attacks cause the enamel of the teeth to break down, resulting in tooth decay.
[0005] If left untreated, the decay will continue to progress through the tooth structure until it reaches the pulp. The pulp chamber houses the nerve and blood supply for the tooth. When decay reaches the pulp, an abscess ensues which is associated with tremendous pain. Once the decay is in the chamber, the only choice of treatments are root canal therapy or extraction of the tooth.
[0006] The best way to prevent decay from forming is by cleaning mouths, thus removing the stray bits of food. If there is no food for the Strep Mutans bacteria to digest, then the bacteria cannot create the acid needed to cause decay.
[0007] The earliest known toothbrush dates back thousands of years. Known as a “chew stick”, this early brush was made by chewing or mashing small twigs or tree roots until the fibers at one end became loose enough to form a rough brush. The cleaning surface had much the same effect as chewing the end of a toothpick. Some native Australian and African people living traditionally still clean their teeth with chew sticks.
[0008] Ancient Chinese, Romans, and Greeks were also oral hygienists. Five thousand years ago, the Chinese thought dental decay was caused by white-colored dental worms with black heads that could be seen when a tooth was extracted. In those days, cures for toothache included purgatives, mouthwashes, massage, and pills. The pills, usually made of grated garlic and salt peter, were inserted into the ear opposite the side of the face affected by the dental pain.
[0009] The early Romans also had their own dental-care preferences. Pliny the Younger of Rome (61-113 A.D.) proclaimed that using a vulture quill as a toothpick would cause halitosis, but using a porcupine quill was acceptable because it “made the teeth firm.” Ancient Roman patricians actually employed special slaves to clean their teeth.
[0010] The Greeks, however, were much more modern. In the third century B.C., Aristotle advised Alexander the Great to rub his teeth every morning with “a thin linen towel, which is somewhat rough.” Using linen as a tooth cleaner is documented as late as 1602, when William Vaughan wrote in Fifteen Directions to Preserve Health that to keep teeth “white and uncorrupt [people should] wash the mouth after every meal, sleep with the mouth somewhat open and in the morning take a line cloth and rub the teeth well within and without.”
[0011] In fifteenth-century Europe, picking the teeth was widely accepted until philosophers began to issue conduct warnings: Rhodes said: “Pick not thy teeth with thy knyfe, but take a stick, or some clean thyng, then doe you not offend.”
[0012] The bristle brush was probably invented by the Chinese. This toothbrush was made of hairs from the neck of a Siberian wild boar which were fixed to a bamboo or bone handle. The bristle brush came to Europe during the seventeenth century. At the time, very few people in the Western world brushed their teeth, and those who did preferred horse hairs, which were softer than those of the wild boar.
[0013] French dentists, who were the most advanced in Europe at the time, advocated the use of toothbrushes in the seventeenth and early eighteenth centuries. It was actually the English in 1780 who gave the world the first modern toothbrush. The handle was made from bone and the bristles were wired into bored holes.
[0014] The toothbrush migrated to the United States and dentists urged pre-Revolutionary Americans to use the bristly toothbrushes in the eighteenth and early nineteenth centuries. In the 1880s, hand-cut and polished cattle thigh bones made excellent toothbrush handles while long-haired hog bristles were inserted by hand, one at a time.
[0015] The first mass-produced toothbrush was made by William Addis of Clerkenwald, England. The first American to patent a toothbrush was H. N. Wadsworth (U.S. Pat. No. 18,653). Companies began to mass-produce toothbrushes in America around 1885. The Pro-phy-lac-tic brush made by the Florence Manufacturing Company of Massachusetts is a good example of an early American made toothbrush. The same company was also the first to sell toothbrushes packaged in boxes.
[0016] In 1937, in the laboratories E. I. DuPont de Nemours & Company, nylon was invented by Wallace H. Carothers. (See, for example, U.S. Pat. No. 2,130,948). The first commercialization of this new material came in 1941 with the introduction of Dr. West's Miracle Tuft toothbrush with nylon bristles.
[0017] At first, even if there were many advantages to using this new brush instead of the one made with wild boar hairs (which fell out, did not dry very well and became full of bacteria), consumers were not entirely satisfied. This is because the nylon bristles were very stiff and hurt the gums. In 1950, Du Pont improved their toothbrush by giving it softer bristles and thus ushering in the modern toothbrush era.
[0018] Despite these dental advances, cleaning small children's teeth continues to be a problem. Between the ages of 6 months and around 3 years, the 20 primary or “baby” teeth erupt. The primary teeth are replaced by 32 permanent or “adult” teeth. The first 28 permanent teeth erupt between 6 and 13 years, the final four third molars, or “wisdom” teeth may erupt between 16-21 years.
[0019] Many parents assume that decay does not matter in primary teeth because the teeth will fall out anyway, but decay in primary teeth poses risks. If a child loses his primary teeth too early because of decay or infection, the permanent teeth will not be ready to erupt. Primary teeth act as a guide for the permanent teeth: if primary teeth are lost too early, the teeth that are left may can tip or move into the vacant space. When the permanent teeth are ready to come into the mouth, there may not be enough room. As a result, teeth may erupt out of their proper positions, leading to malocclusion, crooked or crowded. In addition, the primary teeth help a child learn proper speech.
[0020] Decay in infants is called nursing decay. It can destroy the teeth and most often occurs in the upper front teeth. Nursing decay is severe decay of child's top front baby teeth. It is caused when sugary liquids are frequently consumed from a nursing bottle for a prolonged period of time. Breast-fed children may be at risk if fed on demand during the night and especially if the child sleeps with the mother so that nursing can continue at will.
[0021] Decay occurs when sweetened liquids are given and are left clinging to an infant's teeth for long periods. Many sweet liquids cause problems, including milk, formula and fruit juice. Bacteria in the mouth use these sugars as food. They then produce acids that attack the teeth. Each time a child drinks these liquids, acids attack for 20 minutes or longer. After many attacks, the teeth can decay. This problem is acerbated when a child falls asleep with a bottle during naps or at night. There is decreased salivary flow during sleep and clearance of the liquid from the teeth is slowed. The liquid pools around the upper front teeth and creates an excellent environment to promote the growth of decay-causing bacteria.
[0022] Traditional toothbrushes have proved difficult to adapt for use by parents in infant and small children's mouths, even when downsized. In addition, small children have trouble utilizing traditional toothbrushes to clean their own teeth because of the need to orient the brush perpendicular to the teeth. What is thus needed is device for use in cleaning teeth of infants and small children.
SUMMARY OF THE INVENTION
[0023] A device in accordance with the principals of the present invention provides parents with an improved tool to maintain dental hygiene in infants and small children. A device in accordance with the principals of the present invention also provides small children with an improved tool to clean their own teeth without the need to orient the brush perpendicular to the teeth. A device in accordance with the principals of the present invention provides small children with a tool to train as well, empowering children to brush their own teeth.
[0024] A dental device in accordance with the present invention includes a handle portion and a head portion joined by a joinder. The head portion includes a plurality of projections and a plurality of bristle bunches. In one embodiment, the plurality of projections encircle a core in an about 190 to about 280 degree circumference and the plurality of bristle bunches encircle a core in an about 190 to about 80 degree circumference. In another embodiment, the plurality of projections encircle a core in a plurality of alternating segments interspaced with the plurality of bristle bunches. The plurality of projections can include, but are not limited to a plurality of raised wave-shaped projections, a plurality of circular disks, a plurality of circular grooves, a plurality of ribs, a plurality of spikes and combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a dental device in accordance with the principles of the present invention.
[0026] FIG. 2 is a perspective close-up view of the head of the dental device of FIG. 1 .
[0027] FIG. 3 is a top view of the dental device of FIG. 1 .
[0028] FIG. 4 is a side view of the head of the dental device of FIG. 1 .
[0029] FIG. 5 is a cross-sectional view of the dental device of FIG. 1 .
[0030] FIG. 6 is a perspective view of the dental device of FIG. 1 showing an alternative handle in accordance with the principles of the present invention.
[0031] FIG. 7 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0032] FIG. 8 is a top view of the dental device of FIG. 7 .
[0033] FIG. 9 is a detailed side view of the head of the dental device of FIG. 7 .
[0034] FIG. 10 is a perspective view of a second alternative embodiment of a dental device in accordance with the principles of the present invention.
[0035] FIG. 11 is a top view of the dental device of FIG. 10 .
[0036] FIG. 12 is a detailed side view of the head of the dental device of FIG. 10 .
[0037] FIG. 13 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0038] FIG. 14 is a top view of the dental device of FIG. 13 .
[0039] FIG. 15 is a detailed side view of the head of the dental device of FIG. 13 .
[0040] FIG. 16 is a cut away view of the head of the dental device of FIG. 15 .
[0041] FIG. 17 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0042] FIG. 18 is a top view of the dental device of FIG. 17 .
[0043] FIG. 19 is a detailed side view of the head of the dental device of FIG. 17 .
[0044] FIG. 20 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0045] FIG. 21 is a top view of the dental device of FIG. 20 .
[0046] FIG. 22 is a longitudinal cut away view of the head of the dental device of FIG. 20 .
[0047] FIG. 23 is a latitudinal cut away view of the head of the dental device of FIG. 20 .
[0048] FIG. 24 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0049] FIG. 25 is a top view of the dental device of FIG. 24 .
[0050] FIG. 26 is a longitudinal cut away view of the head of the dental device of FIG. 24 .
[0051] FIG. 27 is a latitudinal cut away view of the head of the dental device of FIG. 24 .
[0052] FIG. 28 is a perspective view of an alternative embodiment of a dental device in accordance with the principles of the present invention.
[0053] FIG. 29 is a top view of the dental device of FIG. 28 .
[0054] FIG. 30 is a longitudinal cut away view of the head of the dental device of FIG. 28 .
[0055] FIG. 31 is a latitudinal cut away view of the head of the dental device of FIG. 28 .
DETAILED DESCRIPTION OF THE INVENTION
[0056] Referring to FIGS. 1-6 , a view of a dental device 10 in accordance with the principles of the present invention is seen. FIG. 1 is perspective view of a dental device in accordance with the principles of the present invention. The dental device 10 includes a handle portion 12 and a joinder portion 16 . The handle portion 12 is preferably comprised of rigid or semi-rigid materials such as, for example, plastic, composite, ceramic or metal.
[0057] The head 14 includes a small rigid or semi-rigid core 18 in the center. The core 18 can be seen in the cross-sectional view of FIG. 5 . In the preferred embodiment, the core is comprised of an extension of the handle portion 12 . The head portion 14 can preferably be co-molded with an elastomeric material or elastomeric foam over the core 18 . In alternative embodiments, alternative materials such as thermoplastic rubber or thermoplastic elastomer can be utilized.
[0058] One of the difficulties in cleaning or brushing small children's teeth is maintaining a traditional toothbrush in the proper orientation such that the bristled head is in contact with the teeth. This can be particularly cumbersome as the parent or other caregiver is used to brushing their own teeth and is called upon to attempt to brush the child's teeth in a backwards orientation from what the caregiver is used to. In addition, small children have trouble utilizing traditional toothbrushes to clean their own teeth because of the need to orient the brush perpendicular to the teeth. A device in accordance with the principals of the present invention also provides small children with an improved tool to clean their own teeth without the need to orient the brush perpendicular to the teeth. A device in accordance with the principals of the present invention provides small children with a tool to train as well, empowering children to brush their own teeth.
[0059] The head portion 14 comprises a plurality of projections 23 . FIG. 2 is perspective close-up view of the head of the dental device of FIG. 1 . FIG. 3 is top view of the dental device of FIG. 1 . FIG. 4 is side view of the head of the dental device of FIG. 1 . In the embodiment depicted in FIGS. 1-6 , the projections 23 comprise a plurality of raised wave-shaped projections 25 . These projections 23 act as a bristle substitute to clean the gum and teeth. The use of these projections enables the child's caregiver to clean or brush the child's teeth holding the handle without particular concern of the exact orientation which is a particular benefit of a dental device in accordance with the principles of the present invention. When these projections are referred to herein as encircling the head in a 360 circumference, it is meant to be inclusive not only of these projections encircling the head in a 360 circumference or sufficiently encircling the head so as to achieve the functionality of enabling the user to clean or brush the child's teeth holding the handle without particular concern of the exact orientation.
[0060] Conventional bristles are mounted by molding holes with tufts of bristles pushed in place by little metal chips that act as staples. Because the dental device of the present invention is sized to be used for infants and small children, there is very limited room to create holes and have enough core material left to have a strong product. In addition, in order to mold the holes radiating out in 360 degrees, a complicated, costly molding tool and special machinery would be required. This is more complicated than a conventional brush where all the holes are molded from one side and then stapled from one side.
[0061] While different sized dental devices in accordance with the principles of the present invention are contemplated as within the scope of the present invention, the dental devices of the present invention are preferably sized for the mouth of a small child. The following exemplary dimensions are given as a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention.
[0062] In this exemplary example, the handle portion is preferably about 3.9 inches in length, the joinder portion is preferably about 0.2 inches in length, and the head is preferably about 1.15 inches in length with an about 0.22 inch radius. The width of the plurality of raised wave-shaped projections and the distance between each of the plurality of raised wave-shaped projections is about 0.03 inches.
[0063] Referring now to FIG. 6 , a perspective view of the dental device of FIG. 1 showing an alternative handle in accordance with the principles of the present invention is seen. The handle portion 12 includes a raised area 27 on which the user can place his or her thumb. The raised area 27 is positioned to approximate the correct distance to the back molars of the mouth of an infant or small child.
[0064] Referring to FIGS. 7-10 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the projections 23 comprise a plurality of circular disks 31 . The circular disks 31 encircle the core in a 360 degree circumference. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of circular disks and the distance between each of the plurality of circular disks is about 0.03 inches.
[0065] Referring to FIGS. 10-12 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the projections 23 comprise a plurality of circular grooves 33 . The circular grooves 33 encircle the core in a 360 degree circumference. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of circular grooves and the distance between each of the plurality of circular grooves is about 0.075 inches.
[0066] Referring to FIGS. 13-16 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the projections 23 comprise a plurality of ribs 35 formed in a 360 degree circumference. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of ribs and the distance between each of the plurality of ribs is about 0.03 inches. FIG. 16 shows a cut away view of the head of the dental device of FIGS. 13-15 . It is seen that the plurality of ribs 35 are formed as a plurality of extensions on a circular disk. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the depth of each of the plurality of ribs is about 0.02 inches with each of the plurality of ribs formed at an about 45 degree angle.
[0067] Referring to FIGS. 17-19 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the projections 23 comprise a plurality of spikes 37 formed in a 360 degree circumference. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of spikes and the distance between each of the plurality of spikes is about 0.033 inches, with the angle between each adjacent of the plurality of spikes about 30 degrees.
[0068] Referring to FIGS. 20-23 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the plurality of projections comprises a plurality of circular disks 31 that encircle the core in an approximately 270 degree circumference. Contained in the remaining approximately 90 degrees of the circumference are a plurality of bristle bunches 40 . In a preferred embodiment, the bristles can be comprised of nylon. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of circular disks is about 0.05 inches, the distance between each of the plurality of circular disks is about 0.04 inches, the diameter of the bristle bunch is about 0.06 inches, while the distance between each of the plurality of bristle bunches is about 0.03 inches. In alternative embodiments, the plurality of projections can comprise a plurality of circular grooves, a plurality of ribs, a plurality of spikes or other such projections.
[0069] Referring to FIGS. 24-27 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the plurality of projections comprises a plurality of circular disks 31 that encircle the core in an approximately 200 degree circumference. Contained in the remaining approximately 160 degrees of the circumference are a plurality of bristle bunches 40 . In a preferred embodiment, the bristles can be comprised of nylon. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of circular disks is about 0.05 inches, the distance between each of the plurality of circular disks is about 0.04 inches, the diameter of the bristle bunch is about 0.06 inches, while the distance between each of the plurality of bristle bunches is about 0.03 inches. In alternative embodiments, the plurality of projections can comprise a plurality of circular grooves, a plurality of ribs, a plurality of spikes or other such projections.
[0070] Referring to FIGS. 28-31 , an alternative embodiment of a dental device in accordance with the principles of the present invention is seen. In this alternative embodiment, the plurality of projections comprises a plurality of circular disks 31 that alternate in encircling the core with a plurality of bristle bunches 40 . In one embodiment, the circular disks 31 can comprise three segments of approximately 110 degrees alternating with three rows comprising the plurality of bristle bunches. In a preferred embodiment, the bristles can be comprised of nylon. Thus, in one embodiment the angle (α) between the mid-pont of bristle bunches 40 is about 120 degrees. As a non-limiting illustrative example of the size of a dental device in accordance with the principles of the present invention, the width of the plurality of circular disks is about 0.05 inches, the distance between each of the plurality of circular disks is about 0.04 inches, the diameter of the bristle bunch is about 0.06 inches, while the distance between each of the plurality of bristle bunches is about 0.03 inches. In alternative embodiments, the plurality of projections can comprise a plurality of circular grooves, a plurality of ribs, a plurality of spikes or other such projections.
[0071] It should be understood that various changes and modifications to the preferred embodiments described herein would be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | The present invention provides a dental device preferably for infants and small children. A dental device in accordance with the present invention includes a handle portion and a head portion joined by a joinder. The head portion includes a plurality of projections and a plurality of bristle bunches. In one embodiment, the plurality of projections encircle a core in an about 190 to about 280 degree circumference and the plurality of bristle bunches encircle a core in an about 190 to about 80 degree circumference. In another embodiment, the plurality of projections encircle a core in a plurality of alternating segments interspaced with the plurality of bristle bunches. The plurality of projections can include, but are not limited to a plurality of raised wave-shaped projections, a plurality of circular disks, a plurality of circular grooves, a plurality of ribs, a plurality of spikes and combinations thereof. | 0 |
BACKGROUND AND BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to power transmissions and, more particularly, to power transmissions that are program controlled so as to provide substantially enhanced flexibility in terms of control of a machine of the type that operates on a workpiece.
In a number of manufacturing operations, where a workpiece, which may be textile material, sheet material, such as metal, glass or plastic, or material handling apparatus, undergoes sequences of operations which may be repeated cyclically, a number of types of indexing mechanisms have been employed to move various mechanical elememts to carry out the sequence of operations on the workpiece. For example, in the carpet tufting field, it has been the practice to employ rotating cam surfaces to shift a needle bar to impress stitched patterns on a carpet backing. Likewise, in handling lumber and sheet metal, it is conventional to employ templates to carry out the function of guiding a tool through a series of mechanical motions to cut or otherwise form the workpiece, as desired.
In operations of the foregoing as well as other types, it has long been desired to expand the flexibility of the types of operations that can be effected by the work tool to correspondingly expand the variety of types of products that may be obtained thereby.
One manner of achieving this goal has been to resort to rather complicated and expensive modifications of existing machinery so as to render the machinery responsive to mechanically or electrically readable program sources such as magnetic or perforated tapes or the like. Thus, where the market demand has been such to justify the investments required to modify or construct such programmable devices, the versatility of operations that could be carried out has been limited only by the quantity and quality of intelligence that could be impressed on a program such as a magnetic or perforated tape or optically scannable medium. See, as examples, U.S. Pat. Nos. 3,502,044, 3,029,758 and 3,863,310.
While arrangements such as the foregoing are useful for their intended purposes, they suffer from the disadvantage that they in general require the wholesale replacement of existing equipment in order to take advantage of the flexibility and variety afforded by a program controlled work tool.
Is is an object of the present invention to provide power transmission apparatus, the output of which is readily controlled by a programmed source, yet which can be easily linked with an existing indexable tool. Additionally, the programmable power transmission of the present invention is capable of use in a wide variety of manufacturing applications where indexed tool operations are employed. Further, the apparatus of the present invention will afford all of the advantages attendant upon employment of a programmed source as the conrol medium for an indexable apparatus whether incorporated into existing machinery, or when forming the basis of entirely new manufacturing techniques.
To summarize the present invention, the apparatus includes a conventional indexing mechanism which converts continuous rotary power into intermittent rotary power which is continuously fed to oppositely rotating shafts. Dual coupling mechanisms are employed to transmit the output from one or the other of the rotating shafts to an output shaft. Selection of the coupling mechanism to be operated is preferably effected by solenoids which, in turn, are controlled by a program source such as a punched tape whereby the direction of rotation, period and, if desired, the speed of the output shaft is controlled by the program.
In a preferred embodiment, the output shaft is connected to a ball screw device which converts rotary motion to linear motion and the output of the ball screw device is connected to the shifting needle bar of a carpet tufting machine. With this arrangement, the number of patterns that can be formed in a tufted carpet can be made variable to an extent limited only by the capacity of the program. Also, the stitch pattern can be non-repeating along the length of the carpet which possibility was not available where cams or templates were used to obtain the shifting of the needle bar of the tufting machine.
The apparatus of the present invention can also be usefully employed with tools which work sheet material where the tool is translated laterally across the path of the material, for example, in cutting, stamping, folding operations or the like. Additionally, the apparatus of the present invention can be employed in sorting conveyed articles in a distribution facility where material, which may be either in liquid or solid form is to be passed from a source to a variety of work stations. Thus, for example, where containers are being fed from a storage facility to a variety of different filling machines having different capacities, the apparatus of the present invention can be employed to direct the required quantity of containers to selected machines according to a predetermined program. In this instance, the apparatus would function to divert the flow path of containers as is required.
The foregoing and other advantages and applications will become apparent as consideration is given to the following detail description of the invention and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the power train of the apparatus of the present invention;
FIG. 2 is a sectional elevational view of a preferred embodiment of the apparatus of the present invention;
FIG. 3 is a view taken along lines 3--3 of FIG. 2;
FIG. 4 is a detailed view of the coupling means of the present invention;
FIG. 5 is an illustration of the application of the present invention to a carpet tufting machine;
FIG. 6 is an illustration of one embodiment of a program source for the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is generally designated at 10 a schematic illustration of the power train of the apparatus of the present invention, which includes a drive shaft 12 which, when the apparatus is operated, is continuously driven by a power source such as an electric motor (now shown). The drive shaft 12 delivers rotary power in a selected direction to an indexing mechanism 14 which may comprise a conventional Geneva gear arrangement, or, more preferably, an index drive such as is disclosed in U.S. Pat. No. 3,572,173. The function of the indexing mechanism 14 is to convert the continuous rotary power delivered by drive shaft 12 to an intermittent rotary motion produced at output shaft 15. For example, for every 360° rotation of input shaft 12, output shaft 15 would be rotated 90°. Of course, it is evident that particular applications of the apparatus will require different ratios of input to output to satisfy the requirements of any particular application of the apparatus.
Output shaft 15 is directly coupled to a first rotary member which, in the illustrated embodiment in a shaft 18 which carries a spur gear 20 which intermeshes with another spur gear 22 mounted on a parallel second rotary member or shaft 24. At this point, it should be noted that it is not necessary that the ratio of spur gears 20 and 22 be equal as, in some applications of the apparatus of the present invention, it may be desirable that the ratios be different. However, it will simplify adjustment of the apparatus if the ratios are maintained as whole numbers.
The ends of the shaft 18 and 24 opposite the respective spur gears 20 and 22 are each provided with coupling means 80 and 82 to enable rotary motion from shafts 18 and 24 to be transmitted, respectively, to a third rotatable member such as shaft 34 and a fourth rotatable member such as shaft 36. As a simplifying factor, shafts 18 and 34 have their axes aligned along a common axis, while the same is true of shafts 24 and 36.
As will be explained in detail hereinafter, coupling means 80 and 82, while schematically illustrated in FIG. 1, have members which are movable with respect to their respective shaft elements to effect coupling of the first and third shafts 18 and 34 and second and fourth shafts 24 and 36. According to the present invention, means which are not illustrated in FIG. 1 are provided for preventing transmission of rotation through both sets of coupling means at the same time. The ends of shafts 34 and 36 opposite the coupling means 80 and 82, respectively, preferably interconnected by pairs of sprocket gears 38 and 40 connected by a sprocket chain 42, or by pulleys and a pulley belt so that shafts 34 and 36 will always rotate together in the same sense in either a clockwise or counter-clockwise direction. It should be noted that shafts 18 and 24, by virture of their spur gear interconnection, will be rotated in opposite directions relative to each other. The apparatus includes an output shaft 44 which, of course, may simply be an extension of shaft 34.
From the foregoing, it will be evident that when coupling means 80 is engaged, output shaft 44 will be rotated in the same direction and at the same speed as shaft 18 whereas, when coupling means 82 is engaged, output shaft 44 will be rotated in the opposite direction by virtue of the connection through sprocket chain 42, and sprocket gears 38 and 40 to shaft 36 which receives rotary power from shaft 24. The speed of rotation of the shaft 44 when coupling means 82 is engaged will be dependent on the gear ratio between spur gears 20 and 22 and the ratio between sprocket gears 38 and 40.
Referring now to FIG. 2, there is illustrated a convenient arrangement of the power train of the present invention as well as the coupling means and control means for the coupling means of the present invention. The same numerals used to designate schematically the elements of the present invention of FIG. 1 will be used in the remaining figures of the drawing to facilitate an understanding of the present invention.
In the arrangement of FIG. 2, the power input shaft 12 is mounted to extend along the upper portion of a housing 46 which includes a base 48 and end walls 50 and 52. The input shaft 12 is supported as is conventional in bearings 54 and 56 in end walls 50 and 52, respectively, and at an intermediate point by bearing 58 located in an intermediate support wall 60 within housing 46.
As previously noted, drive shaft 12 is connected at its end 62 to a power source such as an electric motor preferably by means of a sprocket gear (not shown) which would be mounted on the end 62 of shaft 12 and connected by a chain to the output of the electric motor. Thus, shaft 12 would be continuously driven about its longitudinal axis in one direction, for example, counter-clockwise when viewed from the right side of FIG. 2. The other end of the shaft 12 is connected by a pulley and belt 64 so as to provide a continuous rotary power to an input shaft 13 to an indexing drive 14 which, as noted above, may be a conventional Geneva gear drive or the indexing drive as described in U.S. Pat. No. 3,572,173.
Indexing drive 14 should be selected so that its rotary output at shaft 15 can be varied to meet the operational requirements of the manufacturing procedures in which the apparatus of the present invention is employed. For illustrative purposes, let it be assumed that for every 360° rotation of the input shaft 13 of index drive 14, rotary output shaft 15 will be rotated 90°. Thus, there will be a dwell period where shaft 15 will not be rotating, the duration of which is dependent on the speed of rotation of the input shaft 12. Of course, the speed of rotation of output shaft 15 will also be dependent on the gear ratio of the elements within the indexing drive 14, as is conventional.
Shaft 15 is directly coupled to a first rotary member of the apparatus of the present invention which is shaft 18. Any conventional coupling mechanism may be employed such as the illustrated interiorly slotted cylinder 66, the slots of which interfit with splines on the ends of shafts 15 and 18, as at 68.
Shaft 18 extends through a journal bearing 70 mounted in an opening in wall 52 and is supported intermediate its ends in bearing 72 mounted in a support panel 74 located on the interior of housing 46. Preferably, the longitudinal axis of shaft 18 is aligned with the axis of shaft 15. As shown more clearly in FIG. 3, a parallel shaft 24 is mounted in housing 46 in a manner similar to that as shaft 18. Means in the form of spur gears 20, which is mounted on shaft 18, and 22, which is mounted on shaft 24, serve to interconnect shafts 18 and 24 so that the shafts will be rotated in opposite directions as indicated by the arrows 76 and 78. The support walls and bearings for the shafts in FIG. 3 are deleted for the sake of clarity, but it will be understood that such supports may be identical to that as illustrated in FIG. 2, for shaft 18.
In certain applications, it is desirable that the ratio between gears 20 and 22 be equal, where in other applications of the apparatus of the present invention, it may be desirable that these ratios be on a higher or lower order to accommodate, as previously discussed, specific manufacturing applications. For illustrative purposes, let it be assumed that the ratios between gears 20 and 22 is 1:1.
At the ends of shafts 18 and 24, remote from the wall 52, are elements of the coupling means 80 and 82 of the present invention, the details and operation of which will be explained hereinafter. In general, however, the coupling means 80 serves to couple shaft 18 to another rotary member which, in the illustrated embodiment, is shaft 34, while the coupling means 82 serves to connect shaft 24 to a fourth rotary member, namely, shaft 36 (FIG. 3). Shafts 18 and 34, as well as shafts 24 and 36, are each aligned along common, parallel extending axes indicated at 84 and 86, respectively.
Again referring to FIG. 2, it will be seen that shaft 34 is supported in journal bearings 88 located in an aperture formed in wall 60 as well as by journal bearing 90 disposed in an aperture in end wall 50. Similar rotational supports (not shown) are provided in walls 60 and 50 for shaft 36.
Between walls 50 and 60, sprocket gears 92 and 94 are fixedly mounted, respectively, on shafts 34 and 36 and a chain 96 (FIG. 3) is tightly wrapped around the teeth of the sprocket gears 92 and 94 so that upon rotation of one of the shafts, 34 or 36, the other shaft will be rotated at the same speed and in the same direction where the sprocket gears 92 and 94 have a 1:1 gear ratio. As noted above, however, there will be some applications of the apparatus of the present invention where other gear ratios will be useful.
The end 98 of shaft 34 may be selected as an output shaft of the apparatus 10 and, to this end, a sprocket gear 100 may be fixed on the end of shaft 34. It will be apparent to those skilled in the art, however, that shaft 36 will equally perform the function as the output shaft of the apparatus 10 instead of shaft 34 as the selection between these shafts is arbitrary in this regard.
The coupling means for the two pairs, 18 and 34, and 24 and 26, of rotatable shafts will now be described with respect to the coupling means 80 for shafts 18 and 34, it being understood that coupling means 82 for shafts 24 and 36 is identical with respect to the disposition and function of its elements with one difference which will be described hereinafter.
Coupling means 80 is essentially a clutch mechanism comprising a collar member 102 which is fixed on shaft 18 to be rotatable therewith adjacent the end of shaft 18. In this embodiment, collar member 102 has a bore 104 which fits over the exterior circumference of the shaft 18 and a counter bore 106 which has a slightly larger diameter than that of bore 104. The end of shaft 18 is provided with a reduced diameter portion 108 which extends beyond the face 110 of collar 102. As shown, the face 110 is substantially planar and extends perpendicularly to the longitudinal axis of the shaft 18. Further, as more clearly shown in FIG. 4, face 110 has four radially extending slots 112 each for cooperating with raised teeth 114 formed on a parallel extending face 116 of coupling member 118.
Coupling member 118 has at its center a circular bore 120 which has a diameter sufficient to accommodate portion 108 as well as coil spring 122 which is housed in counter bore 106 and is seated at one end on thrust bearing 123 seated on land 124 of shaft 18. The outer end of coil spring 122 seats on the end wall of chamber 120.
Coupling member 118 is formed with an annular contact surface 126 which extends parallel to, but faces in an opposite direction from the face 116. From contact surface 126, there axially projects a hollow tubular extension 128 which, at its free end, has an enlarged head 146 which serves as a power transmission member and which is disposed in a slotted bore 132 of collar 134. Collar 134 is pinned to the end of shaft 34 as at 136.
Shaft 34 has a reduced diameter extension 138 similar to portion 108 of shaft 18, but on which is fitted a cylindrical bushing 140. Housed between the bushing 140 and the interior of the tubular extension 128 are anti-friction means such as ball bearings 142 provided for the purpose of facilitating sliding movement between coupling member 118 and collar 134.
As seen more clearly in FIG. 4, collar 134 has in bore 132 flat portions 144 which are surfaces that lie along chords of the circumference of the bore 132. As noted previously, the end of the tubular extension 128 of coupling member 118 has an enlarged head 146 which, on opposite sides, has flat surfaces 148, the perpendicular distance between which is equal to the distance between flat surfaces 144 of collar 134. Also, the axial length of the enlarged head 146 is large enough relative to the depth of the bore 132 so that, when the enlarged head 146 is shifted axially relative collar 134, the flat surfaces 148 will remain in engagement with the surfaces 144. Thus, when the coupling member 118 is shifted to the left as viewed in FIG. 2, by means to be described, the flat surfaces 148 of enlarged head 146 will remain sufficiently in parallel contact with the flat surfaces 144 of collar 134 to thereby transmit rotary motion from the coupling member 118 to the collar 134 and thus, to shaft 34.
For manufacturing convenience, collar 134 has portions of its side walls removed as shown in FIG. 4 and a ring 150 is secured as by welding around the free end of the collar 134 in order to provide structural support to the collar that is lost by virtue of the removal of portions of the side walls.
As noted previously, the coupling means 82 is identical to coupling means 80 except for one difference which is the provision of an annular flange 152 (see FIG. 3) which is provided with angularly spaced apart slots 154 extending radially therein. Annular flange 152 may be secured by any suitable means such as welding or by bolting to the projected surface corresponding to surface 126 provided on the clutch member corresponding to clutch member 118 of coupling means 80.
The means for effecting coupling of the coupling means 80 and 82 will now be described.
As shown in FIG. 2, a driven shaft 156 is rotatably mounted on bearings 158 in wall 50 and bearings 160 in wall 60. Shaft 156 extends parallel to drive shaft 12 and receives rotary power from shaft 12 by spur gear 162 mounted on shaft 12 and spur gear 164 mounted on shaft 156. At its interior end, there is mounted on shaft 156 a disc member 16 which, on its inner face, as shown more clearly in FIG. 3, has two cam surfaces 168 and 179 which are in the form of raised axially extending lobes located 180° apart in this embodiment on disc member 166. Cam followers are provided in the form of rollers 172 and 174 which are each rotatably mounted on U-shaped yokes 176 and 178, respectively. As shown more clearly in FIG. 2, for yoke 176, each leg 180 of each yoke is pivotally mounted as at 182 on the base 48 of the housing 46.
Approximately midway along the length of each leg of each yoke there is rotatably mounted a roller such as at 184 and 186 for yoke 176 and at 188 and 190 for yoke 178. As will be subsequently explained in detail, each of the rollers is maintained in continuous contact with the contact surface 126 of its associated clutch member 118.
Secured to the crosspiece of each yoke, approximately at their midpoints, are latch engaging means in the form of blocks 192 on yoke 176 and 194 on yoke 178. As more clearly shown in FIG. 2, the front face of each block is slanted inwardly as at 196.
Means for retaining the coupling means 80 and 82 in their coupled positions are provided in the form of latches 198 and 200, each of which is pivotally mounted as at 202 on a support member 204 which is securely suspended from the top of housing 46 or otherwise suitably mounted with the housing 46.
Opposite the hooked end of each latch 198 and 200, there is pivotally connected an arm shown in FIG. 2 at 206 which is adjustably connected to a solenoid 208 which, when electrically energized by a current draws the arm 206 into the solenoid, thus pivoting latch 198 clockwise about pivot 202 so that the hooked portion will engage surface 196 of the block 192. Pairs of springs as at 210 and 211 may be provided so that when the solenoid 208 is deenergized, the weight of arm 206 serves to pivot the latch 198 counter-clockwise out of engagement with the block 192 against the force of spring 211. Preferably, solenoid 208 will be actuated at a time sufficient to bring the hook of latch 198 into contact with the top of block 192 so that when the cam surface 168 pushes the yoke 176 to a position where the hook of latch 198 clears the end of block 192, spring 211 will snap the latch into engagement with the slanted surface 196. The disposition of the solenoid 268 (FIG. 6) and pivot arms for latch 200 are identical to that as shown for latch 198 and, therefore, need not be described.
According to the present invention, a mechanical safety feature is provided in the form of a pivotably mounted crossbar 212, which is pivotably suspended from platform 214, and extends underneath and contacts both of the latches 198 and 200. As shown in FIG. 3, the pivot point for crossbar 212 is located intermediate its ends as at 216 so that when one of the latches is moved downwardly or clockwise as viewed in FIG. 2, the opposite end of the crossbar will move upwardly to assure that the other latch will be maintained out of engagement with its associated block.
A description of the operation of the apparatus of the present invention, as thus far described, will now be given.
With reference to coupling means 80 of FIG. 2, coil spring 122 is constantly applying force to clutch member 118 tending to shift clutch member 118 to its disengaged position, i.e., to the right as viewed in FIG. 2 so that the key means in the form of the teeth 114 will also be urged out of the recesses 112 in collar 102. Additionally, the spring force exerted on clutch member 118 will always maintain contact surface 126 in engagement with parallel rollers 184 and 186. In addition, rollers 172 and 174 on yokes 176 and 178, respectively, will be continuously maintained in contact with the face of disc 166.
Since, in operation, drive shaft 12 is continuously rotated at constant speed, rotary power will be continually supplied through spur gear 164 to shaft 156 which thereby continuously rotates disc 166 at a constant speed. As a result, as the diametrically disposed cam surfaces 168 and 170 come into contact with the rollers 172 and 174, these rollers and their mounting yokes 176 and 178 will be pivoted in a counter-clockwise direction as viewed in FIG. 2 a distance equal to the height of the cam surfaces 168 and 170 against the force of spring 122 and the corresponding spring in coupling means 82 to thus bring the teeth of clutch member 118 into engagement with the recesses 112 in collar 102 which is the coupled position of the coupling means 80 which also corresponds to the coupling position of the coupling means 82.
If the solenoid 208 and the corresponding solenoid for latch 200 remain de-energized as the cam surfaces 168 and 170 move the coupling means to their coupled positions, as soon as the cam surfaces move past the respective rollers 172 and 174, the coil springs as at 122 will urge the clutch members as at 118 from the key means engaged positions to their key means disengaged positions with respect to collars 102 and 134, simultaneously.
According to the present invention, the speed of rotation of the cam disc 166 should be in timed relationship with the output of the indexing mechanism 14, which is achieved by a proper selection of the gear ratio between spur gears 162 and 164 so that movement of the coupling means 80 and 82 to their coupled positions, as described above, will occur only during the dwell period of indexing mechanism 14, that is, when no rotary motion is being transmitted by indexing mechanism 14 through shaft 15 to shaft 18. In other words, coupling means 80 and 82 will be moved to their coupled positions only at those intervals when none of the shafts 15, 18, 24, 34 and 36 is being subjected to rotary motion.
As previously described in connection with FIG. 1, the direction of rotation of the shaft 34 and, therefore, the output shaft 44 is determined on the basis of which of the two coupling means, 80 or 82, is in its coupled position. Thus, it will be appreciated, that by selectively operating either the solenoid for coupling means 80 or the solenoid for coupling means 82, the direction of rotation of the output shaft 34 can be readily selected as well as the time period of the intermittent rotation in the selected direction by simply maintaining the selected coupling means in its engaged or coupled position corresponding to the condition where the associated solenoid is being energized by an electric current or energized at least during and subsequent to the interval when the cam surfaces 168 and 170 are in contact with the rollers 172 and 174.
To facilitate disengagement of the latches 198 and 200 from the blocks 192 and 194, the height of the cam surfaces 168 and 170 may be sufficient to push the yokes 176 and 178 to the left as reviewed in FIG. 2 so that the hooked portions of the latches will clear the slanted surfaces 196.
From a consideration of the foregoing, it will be readily understood by those skilled in the art that the maintaining of both of the coupling means 80 and 82 in their coupled positions at the end of a dwell period of the indexing mechanism 14 must be avoided in order to prevent damage to the sprocket gears 92 and 96 and the chain 94, as well as to the coupling means themselves. In addition to the safety afforded by the crossbar 212, another back-up safety device of the present invention is illustrated in FIG. 3 and includes a bent pin 218 which is welded or otherwise securely fixed to the inside leg of yoke 176 at a height such that when both of the coupling means are moved to their uncoupled positions by the cam surfaces 168 and 170, the pin 218 will fit into a slot 154 on the annular flange 152 of coupling means 82 to thereby prevent any accidental rotation occurring while both of the coupling means are in their uncoupled position. This feature is chiefly provided to prevent motion from being transferred back from the operated machinery through the normally freely rotatable shafts 34 and 36 to the coupling means.
The apparatus of the present invention is particularly useful in combination with the shifting needle bar of a carpet tufting machine such as is illustrated in FIG. 5, the basic elements and operation of which is described in U.S. Pat. No. 3,026,830 of Mar. 27, 1962.
The operation of the carpet tufting machine 218 of FIG. 5 is intended to produce checkered, stepped, striped or other similar patterns in a carpet. To this end, a plurality of needles 220 are mounted on an arm 222 which extends transverse to a carpet backing sheet indicated by the broken line 224. Yarn loopers 226 are mounted on a support 228 disposed on the opposite side of the carpet backing sheet 224 and serve to hold the loops formed by the needles 220 when the arm 222 is reciprocated by the operating arm 230 along a predetermined path which extends perpendicular to the direction of travel of the carpet backing 224. Operating arm 230 has a head 232 which is slidably mounted on flanges on arm 222. At one end of arm 222 a bracket arm 234 is secured which, in turn, is slidably mounted on a post 236 which extends between the arms of a support yoke 238. Support yoke 238 is securely fixed to a slide beam 240 which is slidably mounted in guide bars 242.
As is conventional in the tufting art, the yarns that are supplied to the various needles 220 may be of different colors and/or textures. Thus, as the carpet backing 224 moves under the needles 220 each needle will form a row of loops upon reciprocation of the operating arm 230. However, upon shifting of the slide beam 240 to the right or left as viewed in FIG. 5, a selected distance or distances, a variety of patterns can be formed on the carpet backing sheet 234.
The apparatus of the present invention, as previously noted, is particularly adapted to effect shifting of the slide beam 240 is a manner controlled by a program so as to substantially increase the variety of types of patterns that can be formed in the carpet. To this end, it is necessary to convert the rotary motion of the output shaft 34 of the apparatus of the present invention to linear motion. This is achieved by the use of conversion means 244 which may be a ball screw device which includes a screw member 246 which at its opposite ends is rotatably mounted in bearing means 248 and 250. One end of the screw member 246 is provided with a sprocket gear 252 which receives rotary power by a chain 254 which is connected to the sprocket gear 100 located on the end 98 of shaft 34 (FIG. 2). A housing 256 is mounted on screw 246 and contains ball-bearings which are in engagement with the threads of screw member 246. Thus, rotation of the screw member 246 will effect linear translation of the housing 256. The housing 256 is securely attached as by an arm 258 to the slide beam 240.
With the apparatus 10 of the present invention and the carpet tufting machine 218, FIG. 5, arranged as described above, it will be seen that when coupling means 80 (FIG. 2) is held in its coupled position by latch 98 which is operated by its solenoid 208, the intermittent rotation of shaft 34 will effect intermittent rotation of the screw member 246 thus causing intermittent shifting of the slide beam 240 which is directly transmitted to needle arm 222. When solenoid 208 is deactivated and the solenoid for latch 200 activated, coupling means 82 will be retained in its coupled position causing shaft 36 to govern the rotation of shaft 34, namely, in the opposite direction which will effect the shifting of slide beam 240 in an opposite direction, thus altering the pattern of the yarns in the carpet backing 224.
It will be apparent that in place of the solenoids, the control arms such as at 206 for the latches 198 and 200 may be connected directly to eccentric wheels or, if desired, controlled by cams where a very limited repeating pattern is desired in the carpet product. Similarly, other mechanical means such as cams can be employed to impart motion to the arm 206 for latch 198 and the other arm for latch 200.
A very advantageous system for controlling the operation of the solenoids of the apparatus 10 of the present invention is illustrated in FIG. 6. It includes a tape reader 260 which senses perforations formed in a tape 262 and delivers current through wires 264 and 266 to solenoids 208 for couplings means 80 and solenoid 268 for coupling means 82. The perforations on the tape 262 constitute a program source which will be reflected in the pattern formed in the carpet backing 224. The simplest type of program consists of two columns or paths of perforations corresponding to the two solenoids 208 and 268. Two reading heads would be provided in reader 260 for sensing the perforations in each path on the tape 262. For example, one perforation in one column would supply a signal to control a circuit so that current will be delivered to solenoid 208 until no perforation in the same column or path is sensed which would alter the circuit and cut off current to the solenoid 208. Thus, the number of perforations in one column or path on the tape 262 would be directly reflected in the amount of shift in the pattern from a straight line set of stitches. The perforations must, of course, be placed in the tape so that at no time are both solenoids energized for the reasons set forth previously. Additionally, an and/or circuit may be employed in the tape reader to assure that current is never delivered to both of the solenoids simultaneously. The tape reader 260 may be any of the conventional type currently available on the market which either employes photosensitive cells to detect the perforations or energized contact switches or the like.
It will be appreciated that the indexing mechanism 14 employed in the apparatus of the present invention will be adjusted to deliver rotary power to the output shaft 34 in timed relationship with the stitching stroke of the operating arm 230. That is to say, when the stitching arm 230 is being operated, the output of the indexing mechanism 14 will be in its dwell mode at least until the operating arm 230 moves to its retracted position wherein the needles 220 are disengaged and are capable of being shifted transversely with respect to the carpet backing 224.
It will also be appreciated that the solenoids 208 and 268 of the apparatus of the present invention can be supplied with current through manual switches, if desired, which would be desirable where discretion is required by the operator in handling a workpiece.
One of the chief advantages of the apparatus of the present invention is the elimination of the necessity of repeatedly intermeshing gears to effect control of the direction of rotation of an output power shaft, as well as the elimination of hydraulic transmission means to obtain reversal of the direction of the rotation of a member. Thus, with the apparatus of the present invention, extremely high speed operations can be employed since the danger of stripping control gears is avoided.
According to another embodiment of the present invention, in place of the latches 198 and 200, magnetic means may be employed to selectively maintain the coupling means 80 and 82 in their coupled positions once the respective yokes 176 and 178 are moved to engage the clutch members. In some applications of the apparatus of the present invention, both the yokes and the latches may be substituted by magnetic clutches that are electrically actuated. However, due to the inherent slippage that occurs upon initial operation of such devices, such arrangements are less preferred where precisely timed transmission of rotary power is required.
While the foregoing has been a description of the preferred embodiment of the present invention, it will be obvious to those skilled in this art that various modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims. | An apparatus for selectively delivering incremental linear motion to a reciprocably mounted tool of a machine, for example, the shifting needle bar of a carpet tufting machine, includes means for intermittently delivering rotary power to a set of oppositely rotatable shafts each having coupling means which, during each dwell period of power delivery, are coupled to driven shafts which are linked to rotate together in the same direction; program controlled latch means are provided for selectively operating one or the other of the coupling means to provide control of the direction and duration of the transmission of motion from the power source. | 3 |
RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of co-pending U.S. Provisional Application Ser. No. 61/424,937, filed Dec. 20, 2010, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND
[0002] 1. Field of Invention
[0003] This invention relates in general to oil and gas production and in particular to a device for coupling together segments of electrical submersible pumps.
[0004] 2. Description of Prior Art
[0005] An electrical submersible pumping (ESP) system for a hydrocarbon producing well is normally installed within casing on a string of tubing or deployed within the tubing itself. Usually the tubing is made up of sections of pipe screwed together. Coiled tubing deployed from a reel may also be used. The motor is often powered with a power cable that is strapped alongside the tubing. The pump is typically located above the motor, is connected to the lower end of the tubing, and pumps fluid through the tubing to the surface. One type of a pump is a centrifugal pump using a plurality of stages, each stage having an impeller and a diffuser. Another type of pump, for lesser volumes, is a progressing cavity pump.
[0006] To contain pressure in the wellbore, ESP systems are typically deployed in a wellbore with the use of a wellhead lubricator. Where the lubricator is generally suspended above an opening to the well using an on-site crane. Safety and environmental concerns limit the maximum length of the lubricator, thereby limiting the size and length of ESPs. Some applications though may require an ESP system to have a length in excess of the maximum length of the lubricator.
SUMMARY OF INVENTION
[0007] Disclosed is an embodiment of a method of engaging sections of a pumping system. In one example embodiment the method includes providing a lower section of the pumping system, where the lower section has a connector with a bore on an upper surface that of the connector. The bore has a cross sectional area that decreases with distance away from its opening. The method further includes anchoring the lower section within production tubing disposed in a subterranean well and providing an upper section of the pumping system. The upper section includes a connector with a downward facing pin. The upper section is oriented into a designated azimuth for coupling engagement with the lower section. Orientation takes place by lowering the upper section onto the lower section and inserting the pin into the opening of the bore. The pin follows a generally circular path as it slides to a lowermost portion of the bore that positions the upper section at a designated azimuth for coupling the upper and lower sections. The upper section is engaged to the lower section when the upper section is oriented as desired. In one example, the lower section includes a lower pumping system with a splined drive shaft and the upper section has a driven shaft with splines. In an example embodiment, an annular coupling on the driven shaft has grooves formed on an inner surface and when the upper section is at the designated azimuth, the splines on the drive shaft are aligned with the grooves in the coupling so that the drive shaft can be inserted into a lower end of the coupling. Optionally, fluid can be vented from inside of the coupling when the drive shaft inserts into the coupling. In another alternative embodiment, fluid is pumped from the wellbore by rotating the drive shaft to rotate the driven shaft via the coupling to pressurize the fluid in the lower section and the upper section. An upward force can optionally be applied onto the upper section to disengage the upper section from the lower section. Alternatively, additional sections can be stacked onto the upper section.
[0008] Also disclosed is an embodiment of an electrical submersible pumping (ESP) system. In one example, the ESP system is made up of a lower tandem selectively anchored inside of production tubing that is disposed in a wellbore. A drive shaft is included in the lower tandem that has an end that projects past the lower tandem and splines on its outer surface. In this example, a connector is provided on an upper end of the lower tandem has an upward facing bore with an cross sectional area that decreases with distance away from an opening of the bore. An upper tandem is set on the upper end of the lower tandem that has a driven shaft inserted into an annular coupling. A connector is provided on a lower end of the upper tandem that has a strategically located pin that points downward. In this example, when the upper tandem lands on the lower tandem and the pin is inserted into the opening of the bore, the pin slides along a side of the bore to a designated azimuth and aligns the grooves in the coupling with splines on the drive shaft as the coupling slides over the drive shaft. In one alternative, the splines on the drive shaft have an upper end with a pointed tip. A vent is optionally formed through a sidewall of the coupling. In one alternate embodiment, the connectors are threadingly mounted on the respective upper and lower ends of the lower and upper tandems, and the pin and bore are adjacent respective outer edges of the connectors on the upper and lower tandems. One alternate embodiment includes a plurality of upward facing bores on the connector on the lower tandem and arranged proximate one another. Optionally, a plurality of downward facing pins are on the connector on the upper tandem. In this example, when the upper tandem is lowered onto the lower tandem, the pins engage an opening of one of the bores. Alternatively, the bores are disposed proximate an outer surface of the connector on the lower tandem, and the pins are disposed proximate an outer surface of the connector on the upper tandem.
[0009] Also provided herein is a through tubing electrical submersible pumping (ESP) system, that in one example embodiment includes a lower tandem pump in selective anchoring within a string of production tubing disposed in a wellbore. A drive shaft with splines is included with the lower tandem pump. A shaft coupling is also included that has an axial passage and grooves formed axially along a sidewall of the passage. The ESP system also includes an upper tandem pump in fluid communication with the lower tandem pump and coupled to an upper end of the lower tandem pump having a driven shaft with a lower end engagedly inserted into the shaft coupling. Connectors are provided on the respective upper and lower ends of the lower and upper tandem pumps for azimuthally orienting the upper tandem so the grooves in the shaft coupling align with splines on the drive shaft as the upper tandem is lowered on to the lower tandem. In one example embodiment, the means for orienting the upper tandem include a series of bores that are disposed along a substantially circular path on an upper surface of the lower tandem. In this example, the path is proximate an outer periphery of the lower tandem. Optionally, the means for orienting the upper tandem includes downwardly pointing pins provided along a substantially circular path on a lower surface of the upper tandem. In this embodiment the path is proximate an outer periphery of the upper tandem. Thus when lowered into the bores, the pins slide in a circular path along a side of the bores to a lowermost position and in a designated azimuth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side sectional view of a connection assembly for a submersible pumping system disposed in a wellbore.
[0011] FIG. 2 is a sectional perspective view of an embodiment of the connection assembly of FIG. 1 .
[0012] FIG. 3 is a side partial section view of tandem submersible pumping systems being coupled together.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0014] FIG. 1 is a side sectional view of a connection assembly 18 for connecting a lower tandem 20 to an upper tandem 22 , which make up a part of a through tubing conveyed (TTC) pumping system 24 . A drive shaft 26 is shown coaxially within the lower tandem 20 and held in place by a bearing assembly 27 . The drive shaft 26 is mechanically coupled to a driven shaft 28 shown set coaxial within the upper tandem 22 . An annular coupling 30 has a lower end and in which an upper end of the drive shaft 26 is inserted. A lower end the driven shaft 28 is shown insert in an upper end of the annular coupling 30 . In the example of FIG. 1 , the drive shaft 26 and driven shaft 28 are maintained substantially coaxial by the annular coupling 30 . Splines 32 shown extending substantially lengthwise along the upper end of the drive shaft 26 mate with grooves or channels 33 provided lengthwise on an inner surface of the coupling 30 . Similarly, splines 34 are formed lengthwise along the lower end of the driven shaft 28 and encounter grooves or channels (not shown) lengthwise in the coupling 30 thereby mechanically affixing the drive shaft 26 with the driven shaft 28 . An optional set screw (not shown) may be included for attaching the coupling 30 to the driven shaft 34 .
[0015] In the example of FIG. 1 , the upper end of the splines 32 narrow to an upward facing edge to form points 38 . The reduced cross sectional area of the points 38 , over that of a “non-pointed” and planar spline embodiment, eases mounting the coupling 30 onto the upper end of the drive shaft 32 by removing potentially interfering structure. The pointed upper ends minimize potential contact surfaces to reduce potential surface contact resistance when inserting the drive shaft 32 into the coupling 30 .
[0016] On the lower end of the upper tandem 22 is a sealing stinger 40 , which is illustrated as an annular extension and protruding a distance within the opening on the upper end of the lower tandem 20 . The stinger 40 of FIG. 1 has an outer diameter configured for sealing contact with the inner circumference of the opening within the lower tandem 20 . Optionally, seals 42 shown on the outer periphery of the sealing stinger 40 may be included to ensure a sealing contact between the lower and upper tandems 20 , 22 . As shown in FIG. 1 , the periphery of the stinger 40 is set radially inward from the outer radius of the upper tandem 22 , thereby defining a downward facing radial shoulder 44 on the outer circumference of the upper tandem 22 . As shown in the coupled configuration of FIG. 1 , the radial shoulder 44 lies in a plane that is substantially perpendicular to an axis A X of the connection assembly 18 . The radial shoulder 44 is shown resting on an upper end of a radial collar 46 that makes up the upper end of the lower tandem 20 .
[0017] Still referring to FIG. 1 , cylindrically shaped pins 48 are shown projecting downward from within the radial shoulder 44 . Alignment bores 50 are formed within the collar 46 and substantially aligned with the axis A X of the connection assembly 18 and the pins 48 . Thus, when the upper and lower tandems 20 , 22 are coupled; the pins 48 are inserted within the alignment bores 50 . In the embodiment of FIG. 1 , the lower ends of the alignment bores 50 are open to the outer radial area of the connection assembly 18 .
[0018] Referring now to FIG. 2 , the pumping assembly 24 of FIG. 1 is shown in a perspective and partial sectional view. The assembly 24 of FIG. 2 is not in a coupled configuration; instead the upper tandem 22 is only partially inserted in with the lower tandem 20 and illustrates an example stage of coupling or decoupling the upper and lower tandems 20 , 22 . More specifically, the lower end of the sealing stringer 40 is inserted within the opening of the lower tandem 20 and with its lower end just past the lower end of the collar 46 . Accordingly, the coupling 30 , which is secured to the driven shaft 28 by the set screw is still above the upper end of the drive shaft 26 . Additionally, the pins 48 are above the alignment bores 50 and out of contact with the collar 46 . The embodiment of FIG. 2 illustrates the lower end of the upper tandem 22 to include a selectively attachable male connector 52 that can be threadingly attached to a housing 54 that houses the upper tandem 22 . Thus in one example embodiment, the male connector 52 includes the sealing stinger 40 , radial shoulder 44 , and pins 48 .
[0019] Similar to the male connector 52 , the upper end of the lower tandem 20 is fitted with a collar like female connector 56 that is threadingly coupled with housing 58 on the outer surface of the lower tandem 20 . The lower tandem 20 can be deployed or removed from a wellbore by coupling a wireline tool (not shown) with a profile 59 illustrated on an inner surface of the female connector 56 The female connector 56 , which is shown an annular element, may be replaced with other designs or configurations mounted on the end of the lower tandem 20 . As seen in the embodiment of FIG. 2 , the alignment bores 50 project into the female connector 56 from a mating surface 60 on the upper terminal end of the female connector 56 . Also, when the upper and lower tandems 20 , 22 are attached, the annular shoulder 44 is in contact with the mating surface 60 . The alignment bores 50 are shown having a wide opening at their upper section and have a cross sectional area that narrows with distance away from the mating surface 60 to define a lower section with cross sectional dimensions more approximate that of the pins 48 than the upper section of the bores 50 . So that when the pin 48 is received within the opening of the alignment bore 50 , the varying cross sectional profile of each bore 50 guides the lower end of each pin 48 along a helical path so that the grooves or channels within the coupling 30 are aligned with the splines 32 on the drive shaft 26 . Strategically positioning the pins 48 and profiling of the bores 50 enables alignment and coupling when the upper tandem 22 is landed onto the lower tandem 20 , even when the pins 48 are azimuthally offset from the lower section of the bores 50 . The pin 48 or pins 48 of FIGS. 1 and 2 could be a single pin or multiple pins. The alignment of the pins 48 and the splines 32 are independent as the tandems 20 , 22 are made up. The upper tandem 22 may rotate in one direction, such as clockwise, while the coupling 30 and splines 32 may rotate in an opposite, or counter-clockwise direction, depending on the respective initial orientation of the upper tandem 22 , coupling 30 , and splines 32 .
[0020] FIG. 3 is a partial sectional view of an example of a pumping system 24 set within tubing 62 that is deployed within a wellbore. In the example of FIG. 3 , the lower tandem 20 represents a stand alone through tubing conveyed pumping system set within the tubing 62 and having a packer 64 set in the annular space between the lower tandem 20 and inner surface of the tubing 62 . A casing 66 circumscribes the tubing 62 within the wellbore, wherein the tubing 62 and casing 66 each are supported from the surface from a wellhead assembly 68 . The lower tandem 20 of FIG. 3 is made up of a motor section 70 having a motor for driving the drive shaft 26 ( FIGS. 1 and 2 ), a seal section 22 set on an upper end of the motor section 70 , and a pump section 74 on the upper end of the seal section 72 . In the embodiment of FIG. 3 , the female connector 56 is mounted on an upper end of the pump section 74 . Further illustrated in the example of embodiment of FIG. 3 is a fluid inlet 76 on the housing of the pump section 74 for receiving wellbore fluid to be pumped.
[0021] The upper tandem 22 is shown as a pump section 74 A similar to the pump section 74 of the lower tandem 20 . Accordingly, the male connector 52 is shown mounted on a lower end of the pump section 74 A. The upper tandem 22 of FIG. 3 is shown being deployed within the tubing 62 from a wireline 78 that can be used for raising and lowering the pump assembly 24 . In the example of FIG. 3 , the wireline 78 is shown suspended through the wellhead assembly 68 . Assembling a multi-tandem submersible pump using the connection systems provided herein allows for staging of pumps within the well bore and without the need of staging above the wellhead 68 .
[0022] In one example embodiment of operation, the lower tandem 20 , with an intake surface installed can be deployed in the tubing 62 and anchored therein, such as with the packer 64 . In this example, the collar 46 is provided on an upper end of the lower tandem 20 with alignment bores 50 facing upward. The upper tandem 22 can then be lowered onto the anchored lower tandem 20 , where the male connector 52 with downward facing pins 48 can engage the bores 50 to rotate the upper tandem 22 into a designated azimuth so that the coupling 30 on the driven shaft 28 can align with and engagingly slide over the drive shaft 26 to fully couple the lower and upper tandems 20 , 22 . In addition to azimuthally orienting the upper tandem 22 , the pins 48 can also prevent the tandems 20 , 22 from rotating with respect to one another during pumping operations. Alternatively, a series of middle tandem pumps (not shown) can be set on the lower tandem 20 for purposes of adding to the stage count. An upper tandem pump can be set on the middle tandem pumps. A pressure segregating apparatus can be strategically disposed in the annular space between the pumps and wellbore. Further, an anchoring device, such as like a packer assembly, can be set on the pumps.
[0023] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, the pins 48 could have lower ends that are pointed. Optionally, the pins 48 could have shapes or profiles that vary along their lengths. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | An electrical submersible pumping (ESP) system for use in a wellbore that can be assembled in the wellbore. Upper and lower pump tandems are fitted with connectors that align the tandems when coupled in the wellbore. The connectors on the lower tandems have bores with enlarged openings on upward facing surfaces. Downward pointing pins are on lower facing surfaces of the connectors on the upper tandems. The cross sectional area of each bore decreases with distance away from the openings, so that as the pins insert into the bores the pins move along a helical path that in turn rotates the upper tandem into a designated azimuth and into alignment with the lower tandem. Properly aligning the upper and lower tandems couples respective drive and driven shafts in the tandems as the upper tandem lands on the lower tandem. | 4 |
[0001] This invention was made with Government support under Contract No. DE-EE0000588.000 awarded by the Department of Energy. The Government has certain rights in this invention.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus to measure permeation of a gas through a membrane.
TECHNICAL BACKGROUND
[0003] Current industry practice for evaluating ultrabarrier performance against water vapor transmission is to use a method that measures actual water transmission. These methods include coulometry (U.S. Pat. No. 7,569,128, MOCON, Inc.), detection of radioactive HTO (U.S. Pat. No. 7,257,990, General Atomics) and optical transmission through calcium (U.S. Pat. No. 7,117,720, Philips Electronics). All three of these approaches have severe limitations. They are all water based, and therefore inherently slow. The time required for establishment of steady state diffusion through a membrane is 5 to 10 times t s , where t s =I 2 /6D. I is the thickness of the membrane, and D is the diffusivity of the permeant. In the case of water diffusing through PET, D is ˜4×10 −9 cm 2 /s at 25 C, so that for a 5 mil (0.005 inch) thick membrane. The minimum measurement time is 10 to 20 hours. In practice, even longer measurement times are required, because the tests involve vapor tranmission rates at or near the limit of sensitivity for each technique. Therefore, significant averaging is required to compensate for the poor signal to noise ratio. As a result, it takes on the order of 1 week to be confident that the transmission rate of an ultrabarrier is at or below the detection limit of either a coloumbic detection system or a radioactive tritium measurement. It takes even longer for the calcium test, because it takes a week or more for the measurement cell to achieve internal equilibrium and start to exhibit a steady state transmission rate.
[0004] In addition to their slow measurement rates, the above techniques are also limited in their sensitivity. According to product literature from MOCON® Minneapolis, Minn., the limit to their measurement technique is 5×10 −4 g/m 2 /day. The limit of the calcium test is an order of magnitude lower: 5×10 −5 g/m 2 /day. The requirement for an ultrabarrier layer for CIGS solar cells or OLED display devices is ˜10 −6 g/m 2 /day, making the tritium test, having a reported detection limit of 2×10 −7 g/m 2 /day, the only technique sufficiently sensitive to verify performance at the required level. Even this test is not really sensitive enough, however, as efficient statistical sampling methods for process control require a continuous measure of the process, both in the out-of-limits and within-limits regimes. The HTO test could only provide such a measure for permeation rates that are just within the control limits, and in most cases could only provide a “pass/fail” type of response. The statistical requirements on “pass/fail” type measurements are so burdensome as to render process control essentially impossible.
[0005] The solution to the first limitation of these methods, the long measurement time, is to use an alternative test gas as a proxy for the water. Helium, for example, has a diffusivity in PET that is 500 times larger than that of water. As a result, t s for helium diffusing through a 5 mil membrane is about 15 seconds, resulting in a measurement time on the order of minutes. Such a substitution is a valid probe of the barrier properties, because permeation through an ultrabarrier occurs via micropores in the inorganic layer, rather than by permeation of the inorganic material itself. Once a correlation has been established between water vapor transmission and helium permeation for the bare PET (or other polymer) substrate, a rapid helium-based test can give a reliable value for the water vapor transmission rate (WVTR).
[0006] The required sensitivity for a test and measurement system based on the helium proxy principle is straightforward to estimate. The noise floor of the calcium test represents a reduction in WVTR over the bare substrate by a factor of 40000. From the permeation rate of helium through PET (˜2×10 −8 scc/cm/s/atm), and assuming a 10 cm diameter membrane and a driving pressure differential of 1 atm, this 40000 reduction factor gives a helium transmission rate of 3×10 −9 scc/s, well within the range of commercial helium mass spectrometer systems. To be useful as a process control technique, however, requires a sensitivity two orders of magnitude below that. Fortunately, state of the art, oil-free helium mass spectrometers are specified to have a sensitivity of 5×10 −12 scc/s which is three orders of magnitude below the calcium test limit.
[0007] Yilvisaker (U.S. Pat. No. 5,361,625) describes passage of gas through a membrane by exposing one side of the film to a test gas and exposing the other side of the film to a carrier gas.
[0008] In practice, however, measurements are limited by the background helium signal due to permeation through elastomer seals. Therefore, there is a need for an apparatus designed to hold ultrabarrier membranes for testing, while reducing or eliminating this background signal.
SUMMARY OF THE INVENTION
[0009] One aspect of the invention is an apparatus comprising
a) a membrane; b) a pair of mating flanges supporting the membrane comprising an input flange and an output flange and an inner seal and an outer seal wherein an annular space is located between the inner and outer seal and wherein the input flange and the membrane define a gas input space and such that the output flange and the membrane define a boundary of the gas outlet space; c) a purge gas inlet line connected to the annular space; d) a purge gas outlet line connected to the annular space; e) a test gas inlet line connected to the gas input space; f) optionally, a test gas outlet line connected to the gas input space; and g) a gas detection apparatus connected to the gas outlet space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an illustration of a membrane under test, clamped between a pair of facing elastomer o-rings.
[0018] FIG. 2 is an illustration of a cross-section of a permeation apparatus.
[0019] FIG. 3 is a graph of He (helium) transmission vs. number of atomic layer deposition layers.
[0020] FIG. 4 is a graph of He (helium) transmission vs water vapor transmission rate.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 illustrates a known embodiment of a test permeation apparatus utilizing a membrane ( 20 ) under test conditions. The membrane is clamped between a pair of facing elastomer o-rings ( 23 ) which are sealing areas. The o-rings are housed by an upper flange ( 24 ) and lower ( 25 ) flange. The upper chamber ( 26 ) contains He (helium) gas at a pressure of about 1 atmosphere. In a known embodiment the elastomer o-ring may be Viton which has a permeability to helium of ˜9×10 −8 scc/cm/s/atm. For an apparatus that can test a 10 cm diameter area of barrier, helium gas will permeate out ( 21 ) of the upper chamber at a high rate: ˜2.5×10 −3 scc/s. The back permeation ( 22 ) of the helium gas depends on the partial pressure of helium in the gap between the upper and lower flanges, which is in turn dependent on the geometry, in this instance, it is considered that the pressure is about 0.008 Torr (i.e. 1/100000 of the pressure in the helium upper chamber). The back-permeation of the helium gas will create a background signal of ˜3×10 −9 scc/s. This signal is comparable to the signal that would be expected from a high performance membrane with a water vapor transmission rate (WVTR) of 10 −7 g/m 2 /day. Measuring such a membrane with the apparatus shown in FIG. 1 would result in a poor signal to noise ratio of 1. The present invention builds on the apparatus described above and lowers the background signal created by back-permeation of the helium gas through the elastomer seals, and as a result improves the signal to noise ratio of the measurement of the permeation rate of gas directly through the membrane.
[0022] A solution to obtaining a lower background signal is to (a) add an outer annular seal to a test apparatus as described above, and have (b) an annular channel located between the inner annular seal and the outer annular seal. The annular channel will be continuously purged with a carrier gas (e.g. nitrogen) sweeping away helium that permeates through the inner annular seal. All other seals found in the test apparatus may be welded or metal-on-metal.
[0023] As illustrated in FIG. 2 , a cross-section of a test permeation apparatus is shown having a membrane 1 . The membrane may be a polymer. The polymer may be selected from, but is not limited to, polyethylene terephthalate, polyethylene naphthalate, polyethylene tetrafluoride, ethylene tetrafluoroethylene, fluorinated ethylene propylene, polynorbornene, polyethersulfone, polycarbonate, or polyimide. The film may be coated with an inorganic coating or an inorganic and organic multi-layer coating to reduce permeation. The inorganic coating may be, but is not limited to, a metal oxide, metal nitride, metal carbide, metal oxynitride, metal oxyboride, or combination thereof, and may be applied by a number of deposition methods, including, but not limited to, atomic layer deposition, chemical vapor deposition, plasma enhanced chemical vapor deposition, sputtering, electron beam evaporation, or thermal evaporation. In multilayer coatings, the organic component may be, but is not limited to, low molecular weight or monomeric acrylates or silicones. The organic layers may or may not be cross-linked after application by, for example, ultraviolet radiation or plasma methods. A pair of mating flanges, an input flange 2 and an output flange 3 support the membrane 1 . The pair of flanges have an inner seal 4 and outer seal 5 . The inner seal 4 and outer seal 5 define an annular space 6 between the inner seal 4 and outer seal 5 . The input flange 2 and the membrane 1 define a gas input space 7 . The output flange 3 and the membrane 1 define a gas outlet space 8 . A purge gas inlet line 9 and outlet line 10 are connected to the annular space 6 . A test gas inlet line 11 is connected to the gas input space. Optionally, a test gas outlet line 12 is connected to the gas input space 7 . A gas detection apparatus 13 is connected to the gas outlet space 8 . The gas detection apparatus 13 may be a mass spectrometer or an ionization gauge. The membrane 1 may be supported by a support screen 14 , which may be in the form of a woven wire screen, or porous metal, ceramic, or glass frit.
EXAMPLES
Example 1
[0024] Helium transmission rates were measured on PET films with Al 2 O 3 films deposited by atomic layer deposition (ALD). The He transmission was compared with typical WVTR data for similar films.
[0025] Five membranes (sample numbers A-E) were supplied, with criteria indicated in the following table 1:
[0000]
TABLE 1
Samples for measurement
Sample
# of ALD
typical WVTR
Number
layers
(mg/m 2 /day)
A
50
370
B
60
26.6
D
70
3.5
E
80
0.1
C
100
.08
[0026] Helium Transmission Measurement Procedure
[0027] Helium transmission measurements were made in a test apparatus (similar to the embodiment illustrated in FIG. 2 ) using a Leybold UL200 portable leak detector. This instrument has an internal calibration source of unknown age, so the absolute calibration is unknown. Also, the scale-to-scale linearity of the instrument is unknown at this point.
[0028] Measurements were made using the following procedure.
1. The membrane was placed on the output flange of the apparatus, and the input flange was fastened down. 2. Nitrogen gas was used to raise the pressure above the film to ˜800 Torr so that the film was in good contact with the support screen. 3. The leak detector was engaged to evacuate the lower chamber. 4. With the pressure in the lower chamber in the 10 −3 mbar range, the atmosphere found in the input space located above the membrane was removed with a rotary vane roughing pump. 5. The system was allowed to remain in this state for 10 to 20 minutes until a steady baseline helium leak rate was observed. 6. Helium gas was admitted into the input space to a pressure of ˜900 Torr. 7. The leak rate was allowed to stabilize (10 to 20 minutes), and was recorded in Table 2.
Results
[0036]
[0000]
TABLE 2
He transmission measurements
He Trans. Rate.
He Pressure
Baseline
Sample #
(mbar l/s)
(Torr)
(mbar l/s)
A
1.0 × 10 −5
911
1.9 × 10 −9
B
3.4 × 10 −6
908
9.0 × 10 −9
D
1.9 × 10 −6
910
6.4 × 10 −9
E
7.9 × 10 −7
914
9.3 × 10 −9
C
3.6 × 10 −7
910
4.7 × 10 −9
[0037] Analysis
[0038] FIG. 3 shows He transmission vs. number of layers. The raw data were adjusted as follows
[0000]
He
rate
=
(
raw
rate
-
baseline
)
×
910
Torr
He
pressure
.
[0039] FIG. 4 shows the same He (helium) transmission data as shown in FIG. 3 , but plotted vs. the typical WVTR numbers given in Table 1. The star symbol plotted in FIG. 4 represents the value the 100 layer sample might be expected to read if the WVTR data tracked the He rate instead of hitting the MOCON vapor transmission instrument noise floor. | The present invention relates to an apparatus to measure permeation of a gas through a membrane. The membrane is mounted on a flange with two sealing areas. The region between the sealing areas defines an annular space. The annular space is swept with a gas in order to carry away any of the permeating gas which may leak through the sealing areas. | 1 |
FIELD OF THE INVENTION
This invention relates to an oil tank device for a motorcycle utilizing internal cavities of components of frame members for an oil tank, which constitute a body frame of the motorcycle.
BACKGROUND OF THE INVENTION
A certain type of motorcycle is equipped with an oil tank device and a conventional oil tank device is provided with an oil tank disposed within vicinity of the head pipe of the body frame.
Engine oil is stored within such an oil tank and fed to respective portions constituting an engine unit so as to lubricate the same. The oil tank is constituted by means of the respective internal cavities of a front rail, a down tube and a bridge tube connecting the tank rail and the down tube and by means of a space defined between two reinforcements secured to both sides of the front tank rail, the down tube and the bridge tube.
An oil passage joint is welded to the lower end portion of the down tube and a rear tank rail is also welded to the lower portion of the front tank rail through means of an oil stopper joint. With the oil tank device described above, however, the difference between the wall thickness of the down tube and the oil passage joint is remarkably large, for example, and since those portions at which the wall thickness difference exists between the down tube and the oil passing joint is not gradually changed when the lower tubes or the like members are welded to the oil passage joint, stress may be concentrated at the welded portion of the oil passage joint.
OBJECT OF THE INVENTION
An object of this invention is to substantially eliminate the defects or drawbacks encountered by means of the conventional technology of this art field and to provide an oil tank device which is capable of sufficiently reducing the stress concentration developed at the body frame of the motorcycle during fabrication of the oil tank.
SUMMARY OF THE INVENTION
The foregoing and other objects can be achieved according to this invention by providing an oil tank device mounted upon the body frame of a motorcycle which is provided with a head pipe and other frame members for storing engine oil therein, and wherein the device comprises a tank rail which is connected to the head pipe and provided with an inner hollow portion, a down tube which is connected to the head pipe so as to extend downwardly and provided with an inner hollow portion, a bridge frame which is connected to the tank rail and down tube and provided with an inner hollow portion, and front reinforcements which are connected to both bilateral sides of the tank rail, the down tube and the bridge frame so as to define an inner space between the front reinforcements, the inner space formed by means of this front reinforcements communicating with the respective inner hollow portions of the tank rail, the down tube and the bridge frame, the lower end portions of the tank rail and the down tube having wall thicknesses which are gradually increased as one proceeds downwardly, and the frame members of the body frame being welded at the most thickened portions of the lower end portions thereof.
According to the oil tank device of the character described above, the lower end portions of the tank rail and the down tube have wall thicknesses which are gradually increased as one proceeds downwardly and, hence, when the frame members of the body frame are welded at the most thickened portions of the lower end portions thereof, the wall thicknesses formed so as to be gradually increased can considerably reduce the stress caused by means of the welding, for example, thereby remarkably reducing the stress concentration upon to the tank rail and down tube by means of the welding process.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features, and attendant advantages of the present invention will become better understood from the following detailed description, when considered in connection with the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is a partial side view of a body frame of a motorcycle according to one embodiment of this invention;
FIG. 2 is a side view of a motorcycle comprising the body frame shown in FIG. 1;
FIG. 3 is a view taken along the arrowed direction A shown in FIG. 1;
FIG. 4 is a sectional view taken along the line 4--4 in FIG. 3;
FIG. 5 is a sectional view taken along the line 5--5 in FIG. 3;
FIG. 6 is an enlarged sectional view of the portion enclosed by means of the chain line oval illustrated in FIG. 1;
FIGS. 7, 8 and 9 are sectional views taken along the lines 7--7, 8--8, and 9--9 in FIG. 1, respectively;
FIG. 10 is a partial side view of the body frame of a conventional oil tank device;
FIG. 11 is a view taken along the arrowed direction B in FIG. 10;
FIG. 12 is a sectional view taken along the line 12--12 in FIG. 11; and
FIG. 13 is an enlarged sectional view of the portion enclosed by means of the chain line circle illustrated in FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In advance of the detailed description of a preferred embodiment construction according to this invention, a conventional oil tank device will be described hereunder with reference to FIGS. 10 to 13 for a better understanding of this invention.
Referring to FIG. 10 showing a body frame of a motorcycle utilized for a conventional oil tank device, this conventional oil tank device is provided with an oil tank 1A disposed within the front portion of the body frame 1. Namely, the oil tank 1A is constituted by means of internal cavities of a front tank rail 2, a down tube 3 and a bridge frame 4 connecting the tank rail 2 and the down tube 3 and by means of a space defined between two reinforcements 5 secured to both sides of the front tank rail 2, the down tube 3 and the bridge frame 4.
Engine oil is stored within the oil tank 1A having the structure described above is positively fed to respective portions of the engine unit so as to lubricate the same.
An oil passage joint 6 is produced by forging means, for example, and is connected to the lower end portion of the down tube 3, and lower tubes 7 are welded to both sides of the joint 6 as shown in FIG. 11. Referring again to FIG. 10, a rear tank rail 9 is welded to the lower portion of the front tank rail 2 through means of an oil stopper joint 8, and side frames 10 coupled to the lower tubes 7 are welded to the rear tank rail 9. The oil stopper joint 8 is manufactured by forging means and is disposed as an end stopper member for the oil tank portion of the front tank rail 2.
Referring to FIG. 12, the wall thickness t 1 of the oil passage joint 6 is thicker than the wall thickness t 2 of the down tube 3, and the oil passage joint 6 and the down tube 3 are connected at respective ends thereof in an overlapped fashion at which the difference between the thicknesses t 1 and t 2 is changed substantially suddenly, such hereinafter being called the thickness changing portion. The thickness changing portion has an axial length l 1 which is very short within the conventional structure. Accordingly, these thicknesses t 1 and t 2 rapidly change within this thickness changing portion and, hence, when the down tube 3 and the lower tube 7 are welded to the oil passage joint 6, severe stress concentration will be caused at the welded portions between the joint 6 and the down tube 3 and between the joint 6 and each of the lower tubes 7.
Referring to FIG. 13, the rear tank rail 9 has a wall thickness t 4 which is thicker than that t 3 of the front tank rail 2. The oil stopper joint 8 is solid and has a considerably large wall thickness of t 5 as shown in FIG. 13, so that the differences in the wall thicknesses between those t 3 and t 5 of the front tank rail 2 and the stopper 8, and between those t 4 and t 5 of the rear tank rail 9 and the stopper 8 are considerably large. Moreover, as is shown in FIG. 13, there is no provision of a thickness changing portion between the front tank rail 2, the rear tank rail 9 and the oil stopper joint 8. According to the construction described above, severe stress concentration will therefore be developed at the welded portions defined between the rear tank rail 9, the front tank rail 2 and the oil stopper joint 8, between the bridge frame 4 and the front tank rail 2, and between the rear tank rail 9 and the side frame 10.
This invention was therefore conceived so as to substantially eliminate the defects of the prior art described above and will be described hereinbelow with reference to FIGS. 1 to 9.
Referring to FIG. 2 showing a side view of a motorcycle comprising a body frame 11, which is shown in detail in FIG. 1, the body frame 11 is provided with a tank rail 12 which is fixed to the head pipe 13, and a down tube 14 which is connected to the head pipe 13 and extends downwardly within the body frame 11. A bridge frame 15 is coupled with the tank rail 12 and the down tube 14 so as to connect them, and front reinforcements 16 are welded to the head pipe 13, the tank rail 12 and the down tube 14, whereby the portion around the head pipe 13 is strengthened so as to increase the rigidity thereof. A front fork 17 is pivotally attached at the head pipe 13 through means of a steering shaft, not shown, so as to be swingable bilaterally with respect to the body frame 11. A handle bar 18 is secured at the top portion of the front fork 17 and a front wheel 19 is rotatably mounted at the lower end portion of the front fork 17. Reference numeral 20 in FIG. 2 designates a front fender.
A pair of side frames 21 are secured upon bilateral side portions of the end portion of the tank rail 12 and a pair of lower tubes 22 are fixedly mounted upon bilateral sides of the end portion of the down tube 14. The rear portion of each lower tube 22 is fixed to the lower portion of each side frame 21 respectively through means of a cross member 23. An engine unit 24 is mounted within a space enclosed by means of the bridge frame 15, the down tube 14, the lower tubes 22 and the side frames 21. A swing arm 26 is supported by means of a swing arm pivot portion 25, as seen in FIG. 2, which is secured to the side frames 21, to so as be swingable with respect to the motorcycle body. A rear wheel 27 is rotatably supported at the free end portion of the swing arm 26. A pair of seat rails 28 fixed at the upper end portions of the side frames 21 extend rearwardly of the body frame 11 and are supported by means of a pair of seat pillars 29. A seat 30 is mounted upon the seat rails 28, and a fuel tank 31 is arranged above the tank rail 12. Reference numeral 32 in FIG. 2 designates a rear fender.
Front reinforcements 16 represented on an enlarged scale in FIG. 1 are welded to the bilateral sides of the tank rail 12, the down tube 14 and the bridge frame 15, as shown in FIGS. 7 to 9, so as to thereby define an inner space 16s. The tank rail 12, the down tube 14 and the bridge frame 15 have tubular or pipe type structures with inner spaces 12s 1 , 14s and 15s respectively. An oil tank compartment 33 is formed by fluidically connecting the inner space 16s of the reinforcements 16 with respective inner spaces 12s 1 , 14s and 15s of the tank rail 12, the down tube 14 and the bridge frame 15.
Namely, an opening 34 shown in FIG. 7 is formed within the lower side of the upper end portion of the tank rail 12 shown in FIG. 1 to so as to fluidically connect the inner space 12s 1 with the inner space 16s, and an opening 35 is formed, as shown in FIG. 6, in the lower side of the lower portion of the tank rail 12 to so as to fluidically connect the inner space 12s 1 with the inner space 15s. An upper opening 36 shown in FIG. 7 and a lower opening, not shown, are respectively formed within upper and lower portions of the section at which the reinforcements 16 are welded to the down tube 14 as shown in FIG. 1, so that the inner space 14s communicates with the inner space 16s. An opening, not shown, similarly formed at the joint of the down tube 14 and the bridge frame 15 so as to establish communication between the inner space 14s and the inner space 15s, and an opening, not shown, is also formed at the welded section of the bridge frame 15 to which front reinforcements 16 are welded so as to thereby establish communication between the inner space 15s and the inner space 16s. As described, the oil tank compartment 33 is defined by means of by the communication established between the inner space 16s and the inner spaces 12s 1 , 14s and 15s.
Referring to FIG. 4, the down tube 14 has a wall thickness t along a first axial portion thereof, but has a thickness t'(t'>t) at the lower end portion 14A thereof which renders the wall structure at that portion substantially thick.
A thickness changing portion represented by means of the dimension L in FIG. 4 is formed in such a manner that the difference between the wall thickness t and t' is gradually and smoothly reduced. An oil passage joint 37 having a relatively short axial length is welded at the lower end portion 14A of the down tube 14 and, as shown in FIG. 3, an oil drain bolt connection 38, an engine suspension boss 39 and the lower tubes 22 are welded at the same portion 14A. An engine suspension reinforcement 39A is also welded to the same portion 14A as shown FIG. 1.
Referring to FIG. 6, the tank rail 12 has a wall thickness t 0 at a first axial portion thereof but has a thickness t' 0 (t' 0>t 0 ) at the lower end portion 12A of the tank rail 12, which renders the wall structure at that portion. A thickness changing portion relatively thick represented by means of the dimension L 0 is formed in such a manner that the difference between the wall thicknesses t 0 and t' 0 is gradually and smoothly reduced.
An oil stopper 40 provided with a semi-spherical head is inserted upwardly into the lower end portion 12A of the tank rail 12, and is welded to the distal end portion of the lower end portion 12A, thereby defining an oil tank portion, corresponding to the inner space 12s 1 of the tank rail 12, and another portion as a non oil tank portion 12s 2 within the tank rail 12. In the case that the outer diameter of the oil stopper 40 is represented by means of the value d, the radius R of the semi-spherical head of the oil stopper 40 is expressed as R=d/2. The oil stopper 40 is so arranged that the top portion of the semi-spherical head of the oil stopper 40 corresponds to the central axis 41 of the opening 35, or is spaced by means of a distance A from the axis 41.
With the lower end portion 12A of the tank rail 12 having the structure described above, each side frame 21 is, as shown in FIG. 1, welded to the insert portion of tank rail 12, which is represented so as to have a dimension h 2 , into which the oil stopper 40 is inserted, and the bridge tube 15 is welded to the non-inserted portion, which is represented so as to have a dimension h 1 , into which the oil stopper 40 is not inserted. A reinforcement 42 is also welded to the insert portion h 2 so as to reinforce the joint between the bridge tube 15 and the tank rail 12.
An oil inlet port 47 is mounted upon the upper portion of the tank rail 12 as seen in FIG. 7 and an oil pump inlet hose 43 connected to a feed pump, not shown, is coupled to the oil passage joint 37, while an oil outlet hose 45 connected to a scavenge pump, not shown, is coupled to an oil return port 44 of the front reinforcement 16. As shown in FIG. 9, an oil hose 46 is connected to the oil return port 44 within the inner space 16s of the front reinforcement 16, that is within the oil tank compartment 33, and extends upwardly so as to communicate with the inner space 12s 1 of the tank rail 12.
When the feed pump and the scavenge pump are driven, engine oil stored within the oil tank compartment 33 is fed to the respective portions of the engine unit 24, including the piston thereof, through means of the oil pump inlet tube 43 as a result of the operation of the feed pump, whereby the oil lubrication can be established at the respective portions of the engine unit 24. The lubricating oil is deposited upon the bottom portion of an oil pan, not shown, and then scavenged and fed into the oil tank compartment 33 through means of the oil pump outlet hose 45 as a result of the operation of the scavenge pump. The lubricating oil is then introduced into the inner space 12s 1 of the tank rail 12 through means of the oil hose 46. The engine oil within the inner space 12s 1 flows down into the inner space 16s through means of the opening 34 and, simultaneously, into the inner space 15s through means of the opening 35. The engine oil within the inner space 16s then flows into inner space 14s through means of the upper opening 36 and the lower opening, not shown, and, simultaneously, into the inner space 15s through means of another opening, not shown. The engine oil within the inner space 15s is also introduced into the inner space 14s through means of an opening, not shown. During this flow of the engine oil, the engine oil can be substantially cooled.
According to the described embodiment, the thickness changing portion L, as shown in FIG. 4, is formed in such a manner that the difference between the wall thicknesses t and t' of the down tube 14 is gradually and smoothly reduced and, hence, when the oil passage joint 37, the oil drain bolt connection 38 and the lower tubes 22 are welded to the lower end portion 14A of the down tube 14, the thickness changing portion L can considerably reduce the stress caused by means of the welding operation. The thickness changing portion L 0 shown in FIG. 6 is formed in such a manner that the difference between the wall thicknesses t 0 and t' 0 of the tank rail 12 is gradually and smoothly reduced, and, hence, when the side frames 21 and the bridge frame 15 are welded to the lower end portion 12A of the tank rail 12, the thickness changing portion L 0 can considerably reduce the stress caused by means of welding operation.
Accordingly, the stress concentration conventionally developed within the tank rail 12 and the down tube 14 by means of the welding operation can be remarkably reduced.
As shown in FIG. 6, the head of the oil stopper 40 is formed with a semi-spherical shape, so that this semi-spherical head of the stopper 40 can reduce weaken the stress caused at the portion, represented by means of the dimension A, of the lower end portion 12A of the tank rail 12, thus preventing severe stress concentration within the portion represented by means of the dimension A.
In addition, the wall thickness of the lower end portion 12A of the tank rail 12 is effectively increased as a result of the insertion or presence of the oil stopper 40 within the end portion 12A, thus considerably improving the rigidity of the portion 12A against external forces and oscillation from a rear cushion unit 48 shown in FIG. 1 and the side frames 21.
Moreover, the oil passage joint 37 welded to the lower portion 14A of the down tube 14 is designed to be smaller than the conventional oil passage joint 6, shown in FIG. 12, thereby reducing the manufacturing cost as well as the body weight.
It is to be understood that this invention is not limited to the described embodiments and many other modifications and changes may be made without departing from the scope and spirit of present invention as embodied within the appended claims. | An oil tank device mounted upon the body frame of a motorcycle provided with a head pipe and other frame members for storing engine oil therein comprises a tank rail connected to the head pipe and provided with an inner hollow portion, a down tube connected to the head pipe so as to extend downwardly and also encompass an inner hollow portion, a bridge frame connected to the tank rail and down tube and provided with an inner hollow portion, and front reinforcements connected to both bilateral sides of the tank rail. The down tube and the bridge frame partially define an inner space between the front reinforcements and the inner space formed by means of front reinforcements communicates with the respective inner hollow portions of the tank rail, the down tube and the bridge frame. The lower end portions of the tank rail and the down tube have wall thicknesses which are gradually increased in the downward direction. The frame members of the body frame are welded at the most thickened portions of the lower portions thereof. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a division of U.S. patent application Ser. No. 09/821,240, filed on Mar. 29, 2001 now U.S. Pat. No. 6,357,107, which is a division of U.S. patent application Ser. No. 09/350,601, filed on Jul. 9, 1999, now issued as U.S. Pat. No. 6,240,622, the specifications of which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to inductors, and more particularly, it relates to inductors used with integrated circuits.
BACKGROUND OF THE INVENTION
Inductors are used in a wide range of signal processing systems and circuits. For example, inductors are used in communication systems, radar systems, television systems, highpass filters, tank circuits, and butterworth filters.
As electronic signal processing systems have become more highly integrated and miniaturized, effectively signal processing systems on a chip, system engineers have sought to eliminate the use of large, auxiliary components, such as inductors. When unable to eliminate inductors in their designs, engineers have sought ways to reduce the size of the inductors that they do use.
Simulating inductors using active circuits, which are easily miniaturized, is one approach to eliminating the use of actual inductors in signal processing systems. Unfortunately, simulated inductor circuits tend to exhibit high parasitic effects, and often generate more noise than circuits constructed using actual inductors.
Inductors are miniaturized for use in compact communication systems, such as cell phones and modems, by fabricating spiral inductors on the same substrate as the integrated circuit to which they are coupled using integrated circuit manufacturing techniques. Unfortunately, spiral inductors take up a disproportionately large share of the available surface area on an integrated circuit substrate.
For these and other reasons there is a need for the present invention.
SUMMARY OF THE INVENTION
The above mentioned problems and other problems are addressed by the present invention and will be understood by one skilled in the art upon reading and studying the following specification. An integrated circuit inductor compatible with integrated circuit manufacturing techniques is disclosed.
In one embodiment, an inductor capable of being fabricated from a plurality of conductive segments and interwoven with a substrate is disclosed. In an alternate embodiment, a sense coil capable of measuring the magnetic field or flux produced by an inductor comprised of a plurality of conductive segments and fabricated on the same substrate as the inductor is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cutaway view of some embodiments of an inductor of the present invention.
FIG. 1B is a top view of some embodiments of the inductor of FIG. 1 A.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1 A.
FIG. 2 is a cross-sectional side view of some embodiments of a highly conductive path including encapsulated magnetic material layers.
FIG. 3A is a perspective view of some embodiments of an inductor and a spiral sense inductor of the present invention.
FIG. 3B is a perspective view of some embodiments of an inductor and a non-spiral sense inductor of the present invention.
FIG. 4 is a cutaway perspective view of some embodiments of a triangular coil inductor of the present invention.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit of the present invention.
FIG. 6 is diagram of a drill and a laser for perforating a substrate.
FIG. 7 is a block diagram of a computer system in which embodiments of the present invention can be practiced.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
FIG. 1A is a cutaway view of some embodiments of inductor 100 of the present invention. Inductor 100 includes substrate 103 , a plurality of conductive segments 106 , a plurality of conductive segments 109 , and magnetic film layers 112 and 113 . The plurality of conductive segments 109 interconnect the plurality of conductive segments 106 to form highly conductive path 114 interwoven with substrate 103 . Magnetic film layers 112 and 113 are formed on substrate 103 in core area 115 of highly conductive path 114 .
Substrate 103 provides the structure in which highly conductive path 114 that constitutes an inductive coil is interwoven. Substrate 103 , in one embodiment, is fabricated from a crystalline material. In another embodiment, substrate 103 is fabricated from a single element doped or undoped semiconductor material, such as silicon or germanium. Alternatively, substrate 103 is fabricated from gallium arsenide, silicon carbide, or a partially magnetic material having a crystalline or amorphous structure. Substrate 103 is not limited to a single layer substrate. Multiple layer substrates, coated or partially coated substrates, and substrates having a plurality of coated surfaces are all suitable for use in connection with the present invention. The coatings include insulators, ferromagnetic materials, and magnetic oxides. Insulators protect the inductive coil and separate the electrically conductive inductive coil from other conductors, such as signal carrying circuit lines. Coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides, increase the inductance of the inductive coil.
Substrate 103 has a plurality of surfaces 118 . The plurality of surfaces 118 is not limited to oblique surfaces. In one embodiment, at least two of the plurality of surfaces 118 are parallel. In an alternate embodiment, a first pair of parallel surfaces are substantially perpendicular to a second pair of surfaces. In still another embodiment, the surfaces are planarized. Since most integrated circuit manufacturing processes are designed to work with substrates having a pair of relatively flat or planarized parallel surfaces, the use of parallel surfaces simplifies the manufacturing process for forming highly conductive path 114 of inductor 100 .
Substrate 103 has a plurality of holes, perforations, or other substrate subtending paths 121 that can be filled, plugged, partially filed, partially plugged, or lined with a conducting material. In FIG. 1A , substrate subtending paths 121 are filled by the plurality of conducting segments 106 . The shape of the perforations, holes, or other substrate subtending paths 121 is not limited to a particular shape. Circular, square, rectangular, and triangular shapes are all suitable for use in connection with the present invention. The plurality of holes, perforations, or other substrate subtending paths 121 , in one embodiment, are substantially parallel to each other and substantially perpendicular to substantially parallel surfaces of the substrate.
Highly conductive path 114 is interwoven with a single layer substrate or a multilayer substrate, such as substrate 103 in combination with magnetic film layers 112 and 113 , to form an inductive element that is at least partially embedded in the substrate. If the surface of the substrate is coated, for example with magnetic film 112 , then conductive path 114 is located at least partially above the coating, pierces the coated substrate, and is interlaced with the coated substrate.
Highly conductive path 114 has an inductance value and is in the shape of a coil. The shape of each loop of the coil interlaced with the substrate is not limited to a particular geometric shape. For example, circular, square, rectangular, and triangular loops are suitable for use in connection with the present invention.
Highly conductive path 114 , in one embodiment, intersects a plurality of substantially parallel surfaces and fills a plurality of substantially parallel holes. Highly conductive path 114 is formed from a plurality of interconnected conductive segments. The conductive segments, in one embodiment, are a pair of substantially parallel rows of conductive columns interconnected by a plurality of conductive segments to form a plurality of loops.
Highly conductive path 114 , in one embodiment, is fabricated from a metal conductor, such as aluminum, copper, or gold or an alloy of a such a metal conductor. Aluminum, copper, or gold, or an alloy is used to fill or partially fill the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. Alternatively, a conductive material may be used to plug the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. In general, higher conductivity materials are preferred to lower conductivity materials. In one embodiment, conductive path 114 is partially diffused into the substrate or partially diffused into the crystalline structure.
For a conductive path comprised of segments, each segment, in one embodiment, is fabricated from a different conductive material. An advantage of interconnecting segments fabricated from different conductive materials to form a conductive path is that the properties of the conductive path are easily tuned through the choice of the conductive materials. For example, the internal resistance of a conductive path is increased by selecting a material having a higher resistance for a segment than the average resistance in the rest of the path. In an alternate embodiment, two different conductive materials are selected for fabricating a conductive path. In this embodiment, materials are selected based on their compatibility with the available integrated circuit manufacturing processes. For example, if it is difficult to create a barrier layer where the conductive path pierces the substrate, then the conductive segments that pierce the substrate are fabricated from aluminum. Similarly, if it is relatively easy to create a barrier layer for conductive segments that interconnect the segments that pierce the substrate, then copper is used for these segments.
Highly conductive path 114 is comprised of two types of conductive segments. The first type includes segments subtending the substrate, such as conductive segments 106 . The second type includes segments formed on a surface of the substrate, such as conductive segments 109 . The second type of segment interconnects segments of the first type to form highly conductive path 114 . The mid-segment cross-sectional profile 124 of the first type of segment is not limited to a particular shape. Circular, square, rectangular, and triangular are all shapes suitable for use in connection with the present invention. The mid-segment cross-sectional profile 127 of the second type of segment is not limited to a particular shape. In one embodiment, the mid-segment cross-sectional profile is rectangular. The coil that results from forming the highly conductive path from the conductive segments and interweaving the highly conductive path with the substrate is capable of producing a reinforcing magnetic field or flux in the substrate material occupying the core area of the coil and in any coating deposited on the surfaces of the substrate.
FIG. 1B is a top view of FIG. 1A with magnetic film 112 formed on substrate 103 between conductive segments 109 and the surface of substrate 103 . Magnetic film 112 c(oats or partially coats the surface of substrate 103 . In one embodiment, magnetic film 112 is a magnetic oxide. In an alternate embodiment, magnetic film 112 is one or more layers of a magnetic material in a plurality of layers formed on the surface of substrate 103 .
Magnetic film 112 is formed on substrate 103 to increase the inductance of highly conductive path 114 . Methods of preparing magnetic film 112 include evaporation, sputtering, chemical vapor deposition, laser ablation, and electrochemical deposition. In one embodiment, high coercivity gamma iron oxide films are deposited using chemical vapor pyrolysis. When deposited at above 500 degrees centigrade these films are magnetic gamma oxide. In an alternate embodiment, amorphous iron oxide films are prepared by the deposition of iron metal in an oxygen atmosphere (10 −4 torr) by evaporation. In another alternate embodiment, an iron-oxide film is prepared by reactive sputtering of an Fe target in Ar+O 2 atmosphere at a deposition rate of ten times higher than the conventional method. The resulting alpha iron oxide films are then converted to magnetic gamma type by reducing them in a hydrogen atmosphere.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1A including substrate 103 , the plurality of conductive segments 106 , the plurality of conductive segments 109 and magnetic films 112 and 113 .
FIG. 2 is a cross-sectional side view of some embodiments of highly conductive path 203 including encapsulated magnetic material layers 206 and 209 . Encapsulated magnetic material layers 206 and 209 , in one embodiment, are a nickel iron alloy deposited on a surface of substrate 212 . Formed on magnetic material layer layers 206 and 209 are insulating layers 215 and 218 and second insulating layers 221 and 224 which encapsulate highly conductive path 203 deposited on insulating layers 215 and 218 . Insulating layers 215 , 218 , 221 and 224 , in one embodiment are formed from an insulator, such as polyimide. In an alternate embodiment, insulating layers 215 , 218 , 221 , and 224 are an inorganic oxide, such as silicon dioxide or silicon nitride. The insulator may also partially line the holes, perforations, or other substrate subtending paths. The purpose of insulating layers 215 and 218 , which in one embodiment are dielectrics, is to electrically isolate the surface conducting segments of highly conductive path 203 from magnetic material layers 206 and 209 . The purpose of insulating layers 221 and 224 is to electrically isolate the highly conductive path 203 from any conducting layers deposited above the path 203 and to protect the path 203 from physical damage.
The field created by the conductive path is substantially parallel to the planarized surface and penetrates the coating. In one embodiment, the conductive path is operable for creating a magnetic field within the coating, but not above the coating. In an alternate embodiment, the conductive path is operable for creating a reinforcing magnetic field within the film and within the substrate.
FIG. 3 A and FIG. 3B are perspective views of some embodiments of inductor 301 and sense inductors 304 and 307 of the present invention. In one embodiment, sense inductor 304 is a spiral coil and sense inductor 307 is a test inductor or sense coil embedded in the substrate. Sense inductors 304 and 307 are capable of detecting and measuring reinforcing magnetic field or flux 309 generated by inductor 301 , and of assisting in the calibration of inductor 301 . In one embodiment, sense inductor 304 is fabricated on one of the surfaces substantially perpendicular to the surfaces of the substrate having the conducting segments, so magnetic field or flux 309 generated by inductor 301 is substantially perpendicular to sense inductor 304 . Detachable test leads 310 and 313 in FIG. 3 A and detachable test leads 316 and 319 in FIG. 3B are capable of coupling sense inductors 304 and 307 to sense or measurement circuits. When coupled to sense or measurement circuits, sense inductors 304 and 307 are decoupled from the sense or measurement circuits by severing test leads 310 , 313 , 316 , and 319 . In one embodiment, test leads 310 , 313 , 316 , and 316 are severed using a laser.
In accordance with the present invention, a current flows in inductor 301 and generates magnetic field or flux 309 . Magnetic field or flux 309 passes through sense inductor 304 or sense inductor 307 and induces a current in spiral sense inductor 304 or sense inductor 307 . The induced current can be detected, measured and used to deduce the inductance of inductor 301 .
FIG. 4 is a cutaway perspective view of some embodiments of triangular coil inductor 400 of the present invention. Triangular coil inductor 400 comprises substrate 403 and triangular coil 406 . An advantage of triangular coil inductor 400 is that it saves at least a process step over the previously described coil inductor. Triangular coil inductor 400 only requires the construction of three segments for each coil of inductor 400 , where the previously described inductor required the construction of four segments for each coil of the inductor.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit 500 of the present invention. Inductor coupled circuit 500 comprises substrate 503 , coating 506 , coil 509 , and circuit or memory cells 512 . Coil 509 comprises a conductive path located at least partially above coating 506 and coupled to circuit or memory cells 512 . Coil 509 pierces substrate 503 , is interlaced with substrate 503 , and produces a magnetic field in coating 506 . In an alternate embodiment, coil 509 produces a magnetic field in coating 506 , but not above coating 506 . In one embodiment, substrate 503 is perforated with a plurality of substantially parallel perforations and is partially magnetic. In an alternate embodiment, substrate 503 is a substrate as described above in connection with FIG. 1 . In another alternate embodiment, coating 506 is a magnetic film as described above in connection with FIG. 1 . In another alternate embodiment, coil 509 , is a highly conductive path as described in connection with FIG. 1 .
FIG. 6 is a diagram of a drill 603 and a laser 606 for perforating a substrate 609 . Substrate 609 has holes, perforations, or other substrate 609 subtending paths. In preparing substrate 609 , in one embodiment, a diamond tipped carbide drill is used bore holes or create perforations in substrate 609 . In an alternate embodiment, laser 606 is used to bore a plurality of holes in substrate 609 . In a preferred embodiment, holes, perforations, or other substrate 609 subtending paths are fabricated using a dry etching process.
FIG. 7 is a block diagram of a system level embodiment of the present invention. System 700 comprises processor 705 and memory device 710 , which includes memory circuits and cells, electronic circuits, electronic devices, and power supply circuits coupled to inductors of one or more of the types described above in conjunction with FIGS. 1A-5 . Memory device 710 comprises memory array 715 , address circuitry 720 , and read circuitry 730 , and is coupled to processor 705 by address bus 735 , data bus 740 , and control bus 745 . Processor 705 , through address bus 735 , data bus 740 , and control bus 745 communicates with memory device 710 . In a read operation initiated by processor 705 , address information, data information, and control information are provided to memory device 710 through busses 735 , 740 , and 745 . This information is decoded by addressing circuitry 720 , including a row decoder and a column decoder, and read circuitry 730 . Successful completion of the read operation results in information from memory array 715 being communicated to processor 705 over data bus 740 .
Conclusion
Embodiments of inductors and methods of fabricating inductors suitable for use with integrated circuits have been described. In one embodiment, an inductor having a highly conductive path fabricated from a plurality of conductive segments, and including coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides has been described. In another embodiment, an inductor capable of being fabricated from a plurality of conductors having different resistances has been described. In an alternative embodiment, an integrated test or calibration coil capable of being fabricated on the same substrate as an inductor and capable of facilitating the measurement of the magnetic field or flux generated by the inductor and capable of facilitating the calibration the inductor has been described.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | The invention relates to an inductor comprising a plurality of interconnected conductive segments interwoven with a substrate. The inductance of the inductor is increased through the use of coatings and films of ferromagnetic materials such as magnetic metals, alloys, and oxides. The inductor is compatible with integrated circuit manufacturing techniques and eliminates the need in many systems and circuits for large off chip inductors. A sense and measurement coil, which is fabricated on the same substrate as the inductor, provides the capability to measure the magnetic field or flux produced by the inductor. This on chip measurement capability supplies information that permits circuit engineers to design and fabricate on chip inductors to very tight tolerances. | 8 |
This application is a division of application Ser. No. 08/249,453 filed May 26, 1994, which is a division of application Ser. No. 07/480,242, filed Feb. 15, 1990 (now U.S. Pat. No. 5,375,161, issued Dec. 20, 1994), which is a continuation-in-part of application Ser. No. 07/439,601, filed Nov. 21, 1989 (now abandoned), which is a continuation-in-part of application Ser. No. 06/841,931, filed Mar. 20, 1986 (now U.S. Pat. No. 4,893,335, issued Jan. 9, 1990), which is a continuation-in-part of application Ser. No. 06/650,821, filed Sep. 14, 1984 (now abandoned).
INCORPORATION BY REFERENCE
The subject matter disclosed and claimed in copending and allowed U.S. application Ser. No. 06/841,931, entitled "Remote Access Telephone Control System", invented by the same inventors and assigned to the same assignee as the instant application, is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention pertains to the telephone equipment art and, more particularly, to a telephone control system which allows subscribers to remotely control a plurality of call handling utilities to predeterminedly direct incoming calls.
Despite the availability of numerous telephone central exchange provided functions, such as "call-forwarding", "three-way calling", "call-waiting" and "speed-dialing", as well as the advent and availability of paging and mobile telephone systems, the completion of a call to a system subscriber can often be a complicated, time consuming and tedious task. Unless the telephone subscriber is located at the telephone which receives calls to his assigned phone number, completion of a call from a calling party, despite the aforementioned services, generally involves the calling party leaving a message and awaiting a call back by the subscriber. Even if the subscriber is accessible via mobile telephone or a paging system, human intervention is commonly required to look up and dial specific mobile telephone or paging numbers to attempt to contact the subscriber. Thus, additional delays and costs are incurred.
In addition, even if the subscriber is on a paging system, the successful direction of a message to the subscriber requires that the subscriber manually inform the system of his whereabouts.
Finally, existing telephone control systems offer very limited control to either the subscriber or the calling party with respect to the processing of calls.
SUMMARY OF THE INVENTION
The present invention provides a method of processing incoming telephone calls directed to a user who is not currently available to answer the incoming telephone calls. This method includes processing an incoming telephone call from a caller directed to a telephone number associated with the user, the telephone number being the telephone number which the user normally utilizes to receive incoming telephone calls, the incoming telephone call having certain status information associated therewith other than simply the telephone number at which the caller is presently located. The status information is based at least in part upon a current call handling mode by which said incoming calls are processed and reflects the current call handling mode. The method also includes transmitting a page to a paging device having a display device associated therewith, the page including the status information for display on its display device.
In another aspect the present invention provides a method of processing incoming telephone calls directed to a user who is not currently available to answer the incoming telephone calls. The method includes processing an incoming telephone call from a caller directed to a telephone number associated with the user, the telephone number being the telephone number which the user normally utilizes to receive incoming telephone calls, the incoming telephone call having certain status information associated therewith other than simply the telephone number at which the caller is presently located. The method also includes transmitting a page to a paging device having a display device associated therewith, the page including said status information for display on the display device, wherein incoming calls are processed in a mode selected by the user and wherein the status information transmitted to the paging device is based at least in part upon the particular mode selected by the user.
In yet another aspect the present invention provides an apparatus for processing incoming telephone calls directed to a user. The apparatus comprises a call processor for processing an incoming telephone call from a caller directed to a telephone number associated with the user where the user receives telephone calls, the incoming telephone call having certain status information generated by said call processor, the status information being based at least in part upon a current call handling mode by which said incoming calls are processed by the call processor and reflects the current call handling mode. The apparatus also includes a transmitter for transmitting a page to a paging device carried by the user, the paging device having a display device associated therewith, the transmitted page including the status information for display on the display device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the various modes of operation and interfacing equipment for the preferred embodiment of the telephone control system;
FIG. 2 is a block diagram illustrating the principle components of the telephone control system;
FIG. 3 is a block diagram of the Communicator;
FIG. 4 is a block diagram of the Ultrasonic Transmitter;
FIG. 5 is a block diagram of the Call Processing facility;
FIG. 6 is a flowchart illustrating operation of the E & M Control Circuit;
FIG. 7 is a diagram illustrating the Subscriber Master Record;
FIG. 8 is a diagram illustrating the Mode Memory;
FIG. 9 is a flowchart of the Main Task for the Call Processing facility;
FIG. 10 is flowchart of the Code Processing Facility--Network Message Task;
FIG. 11 is a flowchart of the Code Processing Facility--Call Termination Task;
FIGS. 12a and 12b form a flowchart of the Call Processing Facility--Call Handler Task;
FIG. 13 is a flowchart of the Call Processing Facility--Dynamic Mode Assignment;
FIGS. 14 and 14a form a flowchart of the Call Processing Facility--Direct Forwarding Function;
FIGS. 15a and 15b form a flowchart of the Call Processing Facility--Announced Forwarding Function;
FIG. 16 is a flowchart of the Call Processing Facility--Priority/Urgent Screen Function;
FIG. 17 is a flowchart of the Call Processing Facility--VIP Code Screen Function;
FIG. 18 is a flowchart of the Call Processing Facility--Branch Routing Function;
FIG. 19 is a flowchart of the Call Processing Facility--Caller Message Center Function;
FIGS. 20a, 20a-1, 20b and 20c a form flowchart of the Call Processing Facility--Voice-Screen Function;
FIGS. 21a and 21b form is a flowchart of the Call Processing Facility--Meet Me Caller Function;
FIG. 22 is a flowchart of the Call Processing Facility--`Send Page` Subroutine;
FIGS. 23a and 23b form is a flowchart of the Call Processing Facility--Command Mode Function;
FIG. 24 is a flowchart of the Call Processing Facility--Command Message Center Function;
FIG. 25 is a flowchart of the Call Processing Facility--Command Forwarding Number Function;
FIG. 26 is a flowchart of the Call Processing Facility--Command Feature Timer Function;
FIG. 27 is a flowchart of the Call Processing Facility--Command Memory Function;
FIG. 28 is a flowchart of the Call Processing Facility--Command Outside Call Function;
FIG. 29 is a flowchart of the Call Processing Facility--Command Help Function;
FIG. 30 is a flowchart of the Call Processing Facility--Command Meet Me Function;
FIGS. 31 and 31a form a flowchart of the Call Processing Facility--Command Branch Route Function;
FIG. 32 is a flowchart of the Call Processing Facility--Command Advanced Features Function;
FIG. 33 is a block diagram illustrating the principle components of the Meet Me Facility;
FIG. 34 is a flowchart of the Meet Me Facility Main Task;
FIG. 35 is a block diagram illustrating the principle components of the Subscriber Access Facility;
FIG. 36 is a flowchart illustrating operation of the E & M Control Circuit for the Subscriber Access Facility;
FIGS. 37a, 37b and 37b-1 form a flowchart of the Subscriber Access Facility Main Task;
FIG. 38 is a block diagram illustrating the principle components of the Communicator Access Facility;
FIG. 39 is a flowchart of the Communicator Access Facility Main Task;
FIGS. 40 and 40a form a flowchart of the Communicator Main Task;
FIG. 41 is a block diagram illustrating the principle components of the Pager Dialing Facility;
FIG. 42 is a flowchart of the Pager Dialing Facility Main Task;
FIG. 43 is a block diagram illustrating the principle components of the Client Services Facility; and
FIG. 44 is a flowchart of the Client Services Facility Main Task.
SPECIFICATION
Overview
FIG. 1 illustrates in block diagram form, the manner in which the Telephone Control System may be used to enhance the accessibility of it's subscribers. As is shown, the Telephone Control System 1 connects with the PSTN 2 via facilities 3. The Telephone Control System 1 may control switch 4, causing it to connect incoming and outgoing trunks.
As is shown, alternate preferred embodiments exist with respect to switch 4.
In the first preferred embodiment, the switch 4 is actually part of the PSTN 1. In this embodiment, the facilities 3 must be capable of transmitting switch control signals from the Telephone Control System 1 to the switch 4. An example of this type of facility is a CENTREX line, which allows the transmission of switch control signals in the form of `hookswitch flashes` and touch tones to initiate call-conferencing and call-transfer. A recently available variation of the CENTREX facility is a CENTREX DID trunk, which not only has the `hookflash` capability, but also provides the called number in the form of Direct-Inward-Dialing digits. This is the form of facility 3 which is referred to in the detailed description of the preferred embodiment. Another variation of the CENTREX facility provides the called number via a separate data-link known as Simplified Message Desk Interface (SMDI).
Copending U.S. application Ser. No. 06/841,931, which issued Jan. 9, 1990, as U.S. Pat. No. 4,893,335, incorporated by reference herein, describes in detail a system for controlling the PSTN switch.
In an alternate preferred embodiment, the switch 4 is part of the Telephone Control System 1. In this embodiment, the facilities 3 need only include standard DID trunks for the incoming calls, and standard outgoing trunks. The access control system 1 controls switch 4 directly, causing it to connect paths between various incoming and outgoing trunks as required.
Again referring to FIG. 1, the Telephone Control System 1 also connects to the PSTN 2 via standard tip-ring phone lines 5, for purposes of communicating with Paging System 6. The Paging System may be any of the commonly known paging systems such as those comprised of transmitters such as Motorola's PACE or Quintton model QT250B and paging terminals such as Glenayre model GL3000XL or BBL System 3, which send encoded messages via radio frequency to cause a unique pager, or beeper, worn by a paging system subscriber, to sound an alert, produce a message in a display, activate a light, vibrate, or produce any of a variety of other alerting mechanisms. Typically, these paging systems will cause a pager to be alerted in response to another individual dialing a phone number which corresponds to that individual's pager. This phone number is routed via the PSTN 2 to a paging terminal via facilities 7, which in turn determines, typically via DID digits, who the call is intended for, and then sends a radio frequency message to alert that individual's pager. To cause a subscriber's pager to be activated, the Telephone Control System 1 then need only come off hook on one of the lines 5, and dial the phone number that corresponds to the subscriber's pager. Although not described in this preferred embodiment, it is anticipated that the Telephone Control System 1 could also interface to a paging system directly via a dedicated data link.
An additional facility 5 connects the Telephone Control System 1 to the PSTN 2. This facility is a trunk which provides the Automatic Number Identification (ANI) of the calling party. An example of such a trunk is the Feature Group D (FGD) trunk which is commonly used by interexchange carriers. The interexchange carriers use the ANI information to properly bill the calling party. The Telephone Control System 1 uses this ANI information in a new and different manner. As will be described in further detail herein, subscribers of the Telephone Control System 1 may program the Telephone Control System 1 by calling it through trunking facilities 5. The access control system 1 automatically acquires the ANI, or phone number of the calling party. This allows the access control system 1 to program the forwarding number for the subscriber without the subscriber needing to manually enter it. Although not described in the preferred embodiment, it is anticipated that other types of facilities which provide ANI information may also be used for this purpose. An example of another type of facility which provides ANI is a CENTEX line with an SMDI data link, which is now available from several types of central offices. The SMDI data link is capable of passing both the called party number and the calling party number (ANI).
Still referring to FIG. 1, The Telephone Control System 1 is also connected to a Packet Radio Transmitter/Receiver 9 via data-link 10. The Packet Radio Transmitter/Receiver 9 may consist of any of the commonly known radio transceivers such as YAESU FT-470 and lCOM IC-u 4AT, equipped with a packet radio interface such as HEATEKIT HK-21. As will be described in further detail herein, the Packet Radio Transmitter/Receiver 9 is used by the Telephone Control System 1 to interface with the portable Communicator device 11, carried by an Telephone Control System subscriber. The Communicator 11 may both send and receive DATA messages via radio frequency. The Communicator 11 may also receive ultrasonic messages from fixed ultrasonic transmitter 12, shown located in room 13. Ultrasonic transmitter 12 continuously transmits the phone number, and, if appropriate, the extension, of the phone 14 located in the same room or a signal indicating an appropriate call control mode for a given situation such as do not disturb in a hospital operating room. It should be noted that, although the preferred embodiment disclosed herein describes transmitter 12 as ultrasonic, it is anticipated that an infrared transmitter may also be used. The ultrasonic transmitter has the advantage that it will pass signals through a layer of clothes, which would be important for example if the subscriber were carrying the Communicator 11 in a shirt pocket.
To aide in the discussion of the illustrative examples which follow, FIG. 1 also shows a subscriber's home 15, with a home phone 16; a subscriber's office 17, with an office phone 18; a cellular telephone system 19, which interfaces to a subscriber's car-phone 20; a factory 21, with a factory phone 22; a pay telephone 23; a subscriber 24 with pager 25; and a caller's telephone 26.
The illustrative examples which follow are intended only to clarify some of the concepts, features, and objects of the invention, and do not define the scope of the invention. In the examples, the greetings include the phrase "ACCESSLINE". It should be understood that the phrase "ACCESSLINE" is a registered trademark of AccessLine Technologies, Inc., and therefore those practicing the present invention will need to select alternate terminology if they are not licensed to use that phrase.
Methods of Call-Handling
Following are several illustrative examples of the various call-handling modes of the Telephone Control System 1.
Direct Forwarding
For the sake of this example, assume that a caller at phone 26 wishes to speak to a subscriber to the access control system 1, and further assume that the subscriber is at home 15, and that he has preprogrammed the system to `direct forward` his calls to him at his home phone 16. The caller dials the access number for the subscriber, and the PSTN delivers the call to the Telephone Control System 1 via facilities 3. The facilities 3 provide the access control system 1 with the called party information (DID) digits. The Telephone Control System then refers to it's internal database to determine how to handle the call. The access control system determines that calls for this subscriber are to be handled via `direct forwarding` mode, and that the call is to be forwarded to the subscriber's home. The access control system then dials the subscriber's home on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to home phone 16, causing it to ring, and the subscriber may pick up the phone and connect to the caller. Note that this mode of call-handling is referred to as `direct forwarding` because the call is forwarded without any announcement or prompting from the Telephone Control System 1.
Announced Forwarding
Assume again that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. Also assume that the subscriber is at home 15, and that this time he has preprogrammed the system to `Announce-forward` his calls to him at his home phone 16. Again, the caller dials the access number for the subscriber, and the PSTN delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `announced forwarding` mode, and that the call is to be forwarded to the subscriber's home. The access control system then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. We're Connecting your call." The Telephone Control System then dials the phone number for phone 16 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to home phone 16, causing it to ring, and the subscriber may pick up the phone and connect to the caller.
Forwarding with Page
Assume again that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. Also assume again that the subscriber is at home 15, and that this time he has preprogrammed the system to `Forward with page` his calls to him at his home phone 16. Again, the caller dials the access number for the subscriber, and the PSTN delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the access control system 1 determines that calls for this subscriber are to be handled via `forward with page` mode, and that the call is to be forwarded to the subscriber's home. The access control system then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. We are sending a page to inform your party of the-call. Please stay on the line." The Telephone Control System 1 then dials the phone number for the pager corresponding to this subscriber and informs the caller "We have sent a page to alert your party and will connect you momentarily." The access control system then dials the phone number for phone 16 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to home phone 16, causing it to ring, and the subscriber may pick up the phone and connect to the caller. The subscriber, having been alerted to the incoming call by his pager, was ready to receive it.
Message Center
In some cases the subscriber may not be able to take calls and may wish that his callers simply leave a message. In these cases, the subscriber may program the access control system 1 to connect calls to the subscriber's preselected `message center`. The Telephone Control System 1 may connect calls to either an `internal message center` or an `external message center`. The `external message center` is simply a phone number that the Telephone Control System 1 will forward calls to if in this mode. This may be the phone number for an answering service, a receptionist, a voice mail system, or any other appropriate location as desired by the subscriber. If the subscriber elects to use the `internal message center`, then an example of a typical call may be as follows.
Assume that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. Also assume that the subscriber does not wish to be disturbed and that he has preprogrammed the system to `internal message center` mode. The caller dials the access number for the subscriber, and the PSTN delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `internal message center` mode. The Telephone Control System then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. Your party is not readily available at the moment, however we will connect you to your party's message center where you may leave a detailed message . . . Please leave your message at the tone." The Telephone Control System 1 then records the callers message and saves it for later playback by the subscriber. In addition, should the subscriber have so elected, the access control system 1 may dial the phone number corresponding to the subscriber's pager, to alert the subscriber to the message.
Priority-Call Screening
Assume again that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. This time assume that the subscriber is at his office 17, and that he has preprogrammed the system to send his calls to him at his office via `priority call-screening`, with a message asking the caller to ask for extension 123, which in this example is the extension number of the phone 18 on his desk. Again, the caller at phone 26 dials the access number for the subscriber, and the PSTN 2 delivers the call to the access control system 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `priority call-screening` mode, and that the call is to be forwarded to the subscriber's office. The access control system 1 then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. Your party is not readily available at the moment. If this call is urgent then please touch 0 now and we will attempt to connect you to your party. Otherwise, please hold the line and we will connect you to your party's message center where you may leave a detailed message." If the caller does not touch 0, then the call is delivered to the `message center` as described above. If the caller does touch 0, then the Telephone Control System 1 may inform the caller: "Please standby while we connect your call. When the call is answered please ask for extension number 123." The access control system then dials the preprogrammed lead phone number for the subscriber's office 17 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to the receptionist at office 17, causing it to ring. When the receptionist answers, the caller will ask for extension 123, as he was instructed by access control system 1, and the receptionist may connect the call to the subscriber's desk phone 18.
VIP Code Screening
Assume again that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. This time assume that the subscriber is in his car, and that he has preprogrammed the system to send his calls to him at his car-phone 20 via `VIP code-screening`. In this mode, only those callers who have been told a special VIP code will be able to reach the subscriber. All other callers will be sent to the message center. Again, the caller at phone 26 dials the access number for the subscriber, and the PSTN 2 delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the access control system 1 determines that calls for this subscriber are to be handled via `VIP code-screening` mode, and that the call is to be forwarded to the subscriber's car phone 20. The Telephone Control System 1 then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. Your party is not readily available at the moment. Please enter your VIP code now, or hold the line and we will connect you to your party's message center where you may leave a detailed message." If the caller does not enter the correct VIP code, then the call is delivered to the `message center` as described above. If the caller does enter the VIP code, then the Telephone Control System 1 may inform the caller: "Please standby while we connect your call." The Telephone Control System then dials the telephone number for car-phone 20 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to the cellular telephone system 19, which in turn delivers the call to the car-phone 20.
Voice-Screening
Assume again that a caller at phone 26 wishes to speak to a subscriber of the Telephone Control System 1. This time assume that the subscriber, Mr. Jones, is visiting his client's factory 21, and that he has preprogrammed the system to send his calls to him at this location via `voice-screening`. Again, the caller at phone 26 dials the access number for the subscriber, and the PSTN 2 delivers the call to the access control system 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `voice-screening` mode, and that the call is to be forwarded to his client's factory 21. The access control system 1 then plays a brief greeting to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. Please state your name and the purpose of your call at the tone. After the tone, please stay on the line while we attempt to locate your party and connect your call." The access control system 1 then records the caller's name and business, and then responds: "Thank you, please standby." The access control system then dials the telephone number for factory 21 on an outgoing facility 3, leaving the incoming call on hold. The PSTN 2 then delivers the outgoing call to the lead telephone number of factory 21, which is answered by the factory's receptionist. The Telephone Control System tells the receptionist "We have a call holding for Mr. Jones. Please locate the party." The receptionist pages Mr. Jones via the factory's speaker system, informing him of the call. Mr. Jones then answers the call at phone 22, and enters his Personal Identification Number (PIN) code. The access control system 1 then plays back the callers name and business. The Telephone Control System 1 then asks Mr. Jones: "Please touch 1 to connect the call, 2 to send the caller away, or 3 to send the caller to your message center." In this example, Mr. Jones wishes to speak to the caller, so he touches 1. The Telephone Control System 1 instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call.
Branch-Routing
Assume again that a caller at phone 26 wishes to speak to a subscriber of the Telephone Control System 1. This time assume that the subscriber is not a person, but a business; the ABC Factory Company 21, and that the Telephone Control System 1 has been preprogrammed to handle their calls via `branch-routing` mode. Again, the caller at phone 26 dials the access number for the subscriber, and the PSTN 2 delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `branch-routing` mode. The Telephone Control System 1 then refers to it's memory and plays a pre-recorded `branch-routing` greeting to the caller: "Hello, you have reached the ABC Factory Company. Please touch 1 to speak to the manufacturing manager, 2 to speak to accounts receivable, 3 to speak to accounts payable, 4 to speak to purchasing, or hold the line to speak to the receptionist." Should the caller need help, he will hold the line for a moment, and the Telephone Control System 1 responds: "Please standby." The Telephone Control System then dials the telephone number for the factory's reception phone 22 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call.
Meet-Me
Assume again that a caller at phone 26 wishes to speak to a subscriber to the Telephone Control System 1. This time assume that the subscriber, Mr. Jones, is away from the office today, and that he has preprogrammed the system to handle his calls via `meet-me` mode. Again, the caller at phone 26 dials the access number for the subscriber, and the PSTN 2 delivers the call to the Telephone Control System 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `meet-me` mode. The Telephone Control System 1 then responds by producing audible ringback to the caller, while dialing the phone number for the pager corresponding to this subscriber on facilities 5. The Telephone Control System 1 then plays a brief message to the caller: "Hello, you have reached the **ACCESSLINE** for Mr. Jones. We are paging your party to a phone, please standby. If you are unable to wait you may touch 9 to leave a message. Otherwise please hold the line." The Telephone Control System 1 then places the caller on hold and waits for the subscriber to call in. Meanwhile the subscriber 24 has received the page via his pager 25, and is proceeding to pay phone 23 to answer the call. The subscriber dials his own access number and the PSTN 2 delivers the call to the Telephone Control System 1 via facilities 3. The subscriber then enters his own PIN code and is informed "You have a caller holding for you on your meet-me service. Please touch 4 to be connected to the caller." It is also anticipated that if the caller had hung up or left a message in the meantime, that the subscriber would be so informed. Assuming that the caller is still holding, and that the subscriber touches 4, the access control system 1 instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call.
Methods of Programming
Although various methods of `remotely programmable call forwarding` have been attempted in the prior art, these have proven to have limited widespread appeal due to the complicated and inflexible methods by which the users were required to program the systems. By contrast, the access control system employs a variety of different methods to allow the subscriber to easily and effectively program the operation of the Telephone Control System. Following are several illustrative examples of the various methods a subscriber may employ to program the Telephone Control System 1.
Command Mode
To use the Command Mode method of programming, the subscriber simply dials his own access number from any telephone, and enters his PIN code. The PSTN 2 delivers the call to the Telephone Control System 1 via facilities 3. The Telephone Control System 1 then informs the caller of the current feature which is selected, and then provides the subscriber with a simple menu of options by which he can choose a new feature. For example, in response to the entry of the PIN code, the subscriber may be prompted: "Hello Mr. Jones. Your calls are currently being VIP code screened to your office. Touch 1 to check messages, 2 to change your forwarding number, 3 to select a memory, 8 for advanced features, 9 to make a call, or touch 0 for help." The subscriber may then make his desired selection. Please note that although the preferred embodiment herein discusses the use of touch tone as the signalling method by which the subscriber controls the Command Mode of the access control system, the inventors anticipate that other signalling methods may also be employed, including, but not limited to, rotary dial pulse detection and voice recognition.
Another feature of the Telephone Control System Command Mode allows the subscriber to program `mode memories` which contain the most often used call handling methods for that subscriber. For example, a subscriber may program memory 10 to be announced forwarding to his office, memory 20 to be voice screened forwarding to his home, memory 30 to be message center mode, and so forth.
Weekly Schedule
Subscribers who have some routine to their weekly activities may soon grow weary of constantly calling the Telephone Control System and selecting the same call handling methods at the same time, day after day. For this reason, the weekly schedule feature provides a very real benefit to the subscriber. As an example, let us assume that a subscriber, Mr. Jones, starts work at 8:00 AM every morning, and leaves for home at 5:00 PM in the evening. Let us further assume that he takes an hour for lunch from 12:00 to 1:00 PM each day. The weekly schedule for this subscriber might be pre-programmed into the Telephone Control System's database to be:
______________________________________DAY TIME MODE MEMORY FEATURE______________________________________Mon-Fri 7:30 am 30 Message CenterMon-Fri 8:00 am 10 Announced forwarding to officeMon-Fri 12:00 noon 30 Message centerMon-Fri 1:00 pm 10 Announced forwarding to officeMon-Fri 5:00 pm 20 Voice screen forwarding to home______________________________________
As calls are received by the Telephone Control System for this subscriber, the Telephone Control System 1 refers to this database and determines the correct call handling method for the day of week and time of day, and delivers the call accordingly.
Another feature of the weekly schedule allows the subscriber to override the weekly schedule should his schedule deviate from the preprogrammed sequence. In this way the subscriber can move freely about his routine activites, and only he needs to program the access control system should his schedule change from the normal.
Feature Timer
To illustrate the use of the Feature Timer capability of the Telephone Control System, assume that a subscriber is visiting a client's office for a one hour appointment, and wishes to have his calls forwarded to him at this location during that time. He may use the Command Mode as described above to select announced forwarding mode and change the forwarding number to be the telephone number of his client's phone. When he leaves he intends to change the the call handling mode back to his message center. However, if the subscriber forgets to call the Telephone Control System as he is leaving the client's office, then the client may still continue to receive calls intended for the subscriber. To overcome this problem, the subscriber may have instead used the Feature Timer function when he first called the access control system when he got to the client's office. In this example, the subscriber could have called the access control system, and used Command Mode to select announced forwarding to his client's office. However, instead of hanging up at that point, he could have activated the Feature Timer, programming it to maintain the current mode for one hour and then automatically change the call handling mode to message center mode. In this way, the subscriber would not have to remember to call the Telephone Control System as he leaves the client's office, and the client would not be bothered with the subscriber's calls after he left.
Programming a Forwarding Number Using ANI
One difficulty in prior art implementations of remotely programmable call forwarding devices, is that it takes quite a few digits for the user to call the system, enter an access code, and then enter the forwarding number. One means by which the invention described herein overcomes this difficulty is by employing special trunks which provide the called party number, also referred to as ANI. To see how this improves the ease of programming, consider the following example. Assume that the subscriber is visiting factory 21, and that this is a location that he does not visit regularly, and therefore does not have it's telephone number preprogrammed into the Telephone Control System 1. Further assume, as was discussed earlier, that the access control system 1 is connected to the PSTN with Feature Group D trunks 8 which provide ANI, and which can be reached by dialing an 800 number. To cause his calls to get to him at the factory 21, the subscriber in this example would pick up telephone 22 and dial the 800 number which corresponds to the Feature Group D trunk. The PSTN 2 would deliver the call to the Telephone Control System 1 and the Telephone Control System 1 would receive the ANI information digits containing the telephone number of telephone 22. The subscriber then need only enter his PIN code and the call handling feature memory he wishes to use, which might be memory 40, announced forwarding. The subscriber could then hang up and the Telephone Control System 1 would program the database to send all calls for that subscriber to telephone 22 via announced forwarding. As should be obvious, the sequence of digits entered by the subscriber was shorter than if he had to actually enter the phone number. It should also be pointed out that another advantage of this method of programming is that the same sequence of digits is used to program the system each time. In other words, if the subscriber went to another location and wanted his calls to be sent to him via announced forwarding, he could pick up a phone and dial the exact same sequence of digits as was described above. This makes the programing of the Telephone Control System less demanding on the subscriber since he only has to memorize one sequence to accomplish this function. It is also anticipated by the inventors that a subscriber to this service may employ a `pocket dialer` preprogrammed with this fixed digit sequence, thereby even further simplifying the ease of programming.
Programming the Telephone Control System using Speed Calling and ANI
A well known service offered by many telephone companies is `Speed Calling`. This service allows users to preprogram often used telephone numbers into memories which can be recalled by dialing a one, two, or three digit code. To see how subscribers can use this service to improve the ease of programming the Telephone Control System, consider the following example. Assume that an Telephone Control System subscriber, who lives at home 15, has preprogrammed the access control system with his home phone number 16. Let us further assume, as was discussed earlier, that the Telephone Control System 1 is connected to the PSTN 2 with Feature Group D trunks 8 which provide ANI, and which can be reached by dialing an 800 number, and assume further that an entire 800-NNX has been dedicated to this trunk group, in this example 800-999-XXXX. By this invention, the last four digits of the 800 number will be used to signify the mode memory which is being selected. In this example, also assume that the subscriber has preprogrammed his telco speed dialing feature so that the sequence 2# causes the telephone number 1-800-999-0010 to be dialed, and that the sequence 3# causes the telephone number 1-800-999-0011 to be dialed. In this example, when the subscriber picks up telephone 16 and dials 2#, the speed dialing feature will cause the number 1-800-999-0010 to be dialed. The PSTN 2 will deliver the call to the access control system 1 via Feature Group D trunks 8. The access control system 1 will receive the ANI digits, and referring to it's database recognize the call as originating at the home telephone of one of it's subscribers. It then will invoke the preprogrammed mode memory 10 for that subscriber, which in this example might be voice-screened forwarding to his home phone. As a further example, if the subscriber had dialed 3#, the Telephone Control System 1 would have invoked memory 11 for that subscriber.
Communicator
As described earlier, the Communicator is a portable device carried on the subscriber's person. This example demonstrates some of the ways by which the Communicator can simplify the call handling and programming operations for the Telephone Control System subscriber. Still referring to FIG. 1, assume that the subscriber is carrying a communicator 11 on his belt, and that he has just entered room 13. Also assume that he has selected the `automatic phone number` mode of operation for the Communicator 11. When he enters the room, the Communicator 11 detects a signal from the fixed ultrasonic transmitter 12 located near the ceiling. This signal is decoded by the Communicator 11 and is determined to contain a phone number, which in this example happens to correspond to the phone instrument 14 located in the same room 13. Upon receipt of the ultrasonic signal, the Communicator 11 transmits a brief packet message via radio frequency. This message contains the subscriber's access number and the phone number just received form the ultrasonic transmitter 12. This radio frequency message is detected by packet radio. transceiver 9 and passed on to the access control system 1 via data link 10. The Telephone Control System then changes the forwarding number for this subscriber to be the new number.
Assume now that a caller at phone 26 wishes to speak to this subscriber. The caller dials the access number for the subscriber, and the PSTN delivers the call to the access control system 1 via facilities 3. Upon receiving the DID digits for this subscriber, the Telephone Control System 1 determines that calls for this subscriber are to be handled via `direct forwarding` mode, and that the call is to be forwarded to the subscriber at telephone 14. The access control system 1 then sends a page message to the packet radio transceiver 9 via data-link 10. The packet radio transceiver 9 in turn transmits a radio frequency packet message to Communicator 11, causing the beeper in the Communicator 11 to alert the subscriber to the incoming call. The Communicator 11 may also then send an acknowledgment message back via radio frequency to the packet radio transceiver 9. Meanwhile, the Telephone Control System 1 has begun to dial the phone number for phone 14 on an outgoing facility 3, and instructs the switch 4 to connect the incoming facility to the outgoing facility to complete the call. The PSTN 2 then delivers the call to phone 14, causing it to ring, and the subscriber may pick up the phone and connect to the caller. Continuing the illustrative example, assume that the subscriber completes the call and leaves the room 13. Communicator 11 detects the loss of signal from ultrasonic transmitter 12, and realizes therefore that the subscriber has left the room and is no longer able to receive calls at this location. The Communicator 11 then transmits a brief packet message via radio frequency. This message contains the subscriber's access number and a special message indicating that no phone number is available and that a default mode memory is to be used for call handling. This radio frequency message is detected by packet radio transceiver 9 and passed on to the Telephone Control System 1 via data link 10. The Telephone Control System 1 then changes the method of call handling for this subscriber to the default mode, which may typically be message center mode. It should be obvious now that if the subscriber were to reenter room 13, or to enter another room with a similar ultrasonic transmitter, that a similar sequence of events would occur causing the calls for this subscriber to be routed to the appropriate room. In this way, without any specific action or effort on the part of the subscriber, his calls will follow him from location to location and be handled automatically and properly.
Another feature of the Communicator allows the subscriber to enter a `manual phone number` mode whereby the Communicator will ignore the messages received from the ultrasonic transmitters, maintaining the last used mode or forwarding number.
Another feature of the Communicator allows the subscriber to select a new method of call-handling by touching keys on the Communicator's keypad. This will cause the Communicator 11 to transmit a `new mode memory request` packet message via radio frequency to the packet radio transceiver, which in turn will send the message to Telephone Control System 1 via data-link 10, causing the Telephone Control System 1 to change the call handling method for that subscriber.
DETAILED DESCRIPTION
FIG. 2 is a block diagram of the telephone control system 1. The preferred embodiment of the telephone control system 1 consists of a variety of subsystems, or facilities. A Call Processing Facility (CPF) 100 is shown connected to trunks 3. A Pager Dialing Facility (PDF) 105 is shown connected to telephone lines 5. A Subscriber Access Facility (SAF) 110 is shown connected to trunks 8. A Meet-Me Facility (MMF) 115 is shown connected to lines 120. A Communicator Access Facility (CAF) 125 is shown connected to datalink 10. A Client Services Facility (CSF) 130 is also shown. Each of these facilities is connected to high speed data network 150.
A block diagram of the Communicator 11 is shown in FIG. 3. The operation of the Communicator 11 is controlled by microprocessor 200, which in the preferred embodiment is a single chip microprocessor containing it's own Read-Only-Memory (ROM) and Random-Access-Memory (RAM). A keypad 205, and display 210 are shown connected to microprocessor 10. A transmit data output port 215 is provided by the microprocessor 200. This transmit data is passed to packet data encoder 220 which formats the data into packets before sending the packets to antenna 230 via radio frequency transmitter 225. Radio frequency receiver 235 receives data packets from antenna 230 and passes them to packet data decoder 240, which removes the packet format and passes the raw received data to the receive data input port 245 on microprocessor 200. Output port 250 may be used to apply a tone signal to beeper driver 255 which supplies sufficient current to drive beeper 260 to produce an alerting sound. A transducer 265, capable of receiving signals in the ultrasonic frequency range, passes these signals to a 40 Kilohertz filter and amplifier 270. The resulting signal is applied to detector 275 which removes the 40 Kilohertz component from the signal and passes the resulting serial data to input port 280 of microprocessor 200. Also shown is a crystal oscillator 285 which controls the timing of all operations of the microprocessor 200. Power for the Communicator 11 is supplied by battery 290. Improvements that currently exist in the ART may be made to the ultrasonic transmitter and detector to enhance its ability to communicate the ultrasonic data in the presence of multi-path echoes. These improvements include, but are not limited to: frequency shift keying; the transmission of synchronized data and the use of a clock recovery logic to extract the clock thing over a long integration period resulting in a clock move resistant to echoes; the use of error detecting and correcting codes; and the use of sampling and voting techniques to determine the correct bit value after multiple samples during a bit period, the bit period being determined by the clock recovery logic above. In addition, multiple transmitters may be used as a method of obtaining increased coverage and area transmission diversity.
A block diagram of the Ultrasonic Transmitter 12 is illustrated in FIG. 4. Oscillator 300 provides a 40 Kilohertz signal to one input of AND gate 305. The output of crystal oscillator 310 is applied to divider 311 which produces a 75 Hertz signal to the clock input of 6-bit counter 315. The 6 outputs of counter 315 are applied to the address inputs of Read-Only-Memory 320. Memory 320 is pre-programmed with data representing the phone number of the nearest telephone. This data may contain the area code plus seven digits and the extension number if appropriate. With each digit represented by 4 bits, 14 digits and 8 bits of checksum may be transmitted. Only the least significant bits in ROM 320 need be programmed, as the LSB output 325 is used to apply this data to a second input of AND gate 305. As can be seen, the serial data at 325 will continuously output the phone number at a rate of 75 bits per second. AND gate 305 combines the serial data 325 and the 40 Kilohertz signal from oscillator 300 producing a resultant signal which is applied to transducer driver 330. The output of driver 330 is then applied to transducer 335. As should be obvious, the transducer will be generating a 40 Kilohertz signal while the serial data output 325 is high, and will be generating no signal while the serial data output 325 is low. The data is therefore modulated on the 40 Kilohertz carrier at a rate of 75 baud. The 64 bits from the ROM 320 are thus transmitted in a period of 0.853 seconds. This is adequate for the transmission of a phone number and extension. Although this baud rate is relatively low) it has the advantage of reducing the effect of multipath (reflections of the ultrasonic signal arriving at the receiver at different times and phases), and thus improves the reliability of transmission as compared with higher baud rates.
A block diagram of the Call Processing Facility (CPF) 100 is shown in FIG. 5.
Referring to FIG. 5, CPF trunk interface 400 interfaces the CPF 100 with trunk 3. As was discussed earlier, the preferred embodiment of the telephone control system 1 employs a CENTREX DID trunk. In this embodiment trunk 3 is provided via a 4-wire E&M trunk provisioned with TYPE I signalling, which is well known in the art. This type of trunk provides a 2-wire balanced transmit audio connection, shown terminated by line termination 405. This type of trunk also provides a 2-wire balanced receive audio connection, shown terminated by line termination 410. The E-Lead of trunk 3 is shown connected to the current limiting and overvoltage protection at reference 415. In a similar fashion, the M-Lead of trunk 3 is shown connected to the current limiting and overvoltage protection at reference 420. 2-to-4 wire convertor 425 takes the separate balanced transmit and receive signals from line terminators 405 and 410 and combines them into one single-ended signal at reference 430, which is applied to call processor 435. The E-Lead signal from limiter/protector 415 is passed to current detector 440. As is shown, current detector 440 provides a path for the E-Lead signal through to the negative battery reference of -48 volts at 445. Current Detector 440 also provides an "E-Lead Detect" logic signal indicating the presence of current via the E-lead. This signal is applied to E&M lead control circuit 450. The M-Lead signal for limiter/protector 420 is passed to M-Lead relay 455. This relay is controlled by a "M-Lead Control" signal from control circuit 450. By activating or deactivating relay 455, control circuit 450 is able to take the M-Lead on-hook or off-hook, as the M-Lead will be connected either to -48 volts or to ground. The control circuit 450 outputs an "Incoming Call" signal 470 to buffer 460, and outputs a "Loop Status" signal 475 to call processor 435. The control circuit 450 has as additional inputs a "DID Received" signal 480 from latch 465, and an "On/Off-Hook Control" signal 485 from call processor 435. The output of buffer 460, and the input of latch 465 is applied to CPF internal data bus 490.
Still referring to FIG. 5, the CPF internal data bus 490 connects CPF trunk interface 400, call processor 435, precision busy/ring detector 437, Central Processing Unit (CPU) 495, Random Access Memory (RAM) 500, Disk memory 505, and data network interface 510. Call processor 435 performs the functions of voice record and playback, dual-tone-multi-frequency (DTMF) detection and generation, and call control. The functions of call processor 435 are well known in the art and many products, such as the Model D41B manufactured by Dialogic Corporation, exist commercially which can accomplish these functions. A voice recognition module 436 is shown connected to call processor 435. Voice recognition module 436 allows call processor 435 to detect, on a speaker-independent basis, a simple set of spoken commands from callers. The simple set consists of 16 words including the digits `0` through `9`. This capability, in combination with the DTMF detection capability of the call processor 435, allows caller to either speak their commands, or enter them from a DTMF phone. A commercially available product which performs this voice recognition function is the Model VR/10 manufactured by Dialogic Corporation.
A precision busy/ring detector 437 is shown connected to the audio signal 430 from CPF trunk interface 400. This detector may be used to perform a rapid detection of precise busy and precise ringing signals, even in the presence of voice. Unlike the busy and ring detection functions of Call Processor 435 which require a cadence match as well as a frequency match, precision busy/ring detector 437 does not require a cadence match and is therefore capable of rapidly detecting precise busy and ringing signals even if a party is conferenced in and speaking on the line. This capability is useful in providing the `busy/no-answer option` as will be described later. The functions of precise busy/ring detector 437 are well known in the art, and may be typically implemented as follows. The incoming audio signal is applied to the inputs of several identical circuits, each with center frequencies set to detect a different component of the expected busy or ringing signal. Each of these circuits contains a low Q bandpass filter. This filter prevents out-of-band signals such as voice from interfering with the detection function. The output of the bandpass filter is fed to a zero crossing detector. The output of the zero crossing detector is then fed to a high Q bandpass filter again set at the frequency to be detected. The output of the bandpass filter is then sent to a level detector which provides a positive indication if the incoming signal is above a preset amplitude. The output of the busy/ring detector 437 may be read by CPU 495 via the CPF internal data bus 490.
CPU 495 controls all functions of CPF 100. The software program which the CPU 100 uses is loaded into RAM 500, from disk memory 505. The disk 505 also is used to store a variety of other data including the subscriber database for the telephone control system 1. A data network interface 510 is used to connect the CPF 100 to the other subsystems of the telephone control system 1. Data network interface 510 passes data messages between the CPU 495 and these other subsystems. The functions of data network interface 510 are well known in the art, and many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. Although only one trunk interface 400, one trunk 3, and one call processor 435 are shown in FIG. 5, it should be readily evident to one skilled in the art that additional trunk interfaces and call processors may be added to support additional trunks.
A flowchart of the operation of E&M control circuit 450 is shown in FIG. 6. At reference 600, the control circuit 450 idles waiting for an indication from current detector 440 that the E-Lead has gone off-hook. When the E-Lead does go off-hook, as shown at reference 605, an "Incoming Call" signal is sent to CPU 495 via buffer 460. The control circuit 450 then idles at 610, waiting for an off-hook signal from call processor 435, signifying that the CPU 495 is ready to accept the call. When the off-hook signal is received, the "Loop Status" 475 is set active as shown at reference 615. The M-Lead is then winked by taking M-Lead relay 455 momentarily off-hook, as shown at reference 620. The control circuit 450 then idles again at 625, waiting for the receipt of the "DID Received" signal 480 from CPU 495 via latch 465. Call processor 435 detects the incoming DID digits on it's audio line 430 and decodes the digits passing the digit sequence on to CPU 495. This DID digit sequence represents the `called number` or ACCESS NUMBER of a subscriber to the telephone control system 1. When the CPU 495 receives the DID digits from call processor 435, the CPU 495 sets the "DID Received" signal 480 active, and the control circuit 450 takes the M-Lead off-hook as shown at reference 630. At this point a call has been established, and the control circuit 450 must now wait until either CPU 495 terminates the call, as signified by on/off-hook control signal 485 going on-hook, or by the calling party terminating the call as signified by the E-Lead detect from current detector 440 going on-hook. These functions are accomplished by control circuit 450 as illustrated at references 635 through 670. At 635 a check is made to determine if on/off-hook control signal 485 is on-hook. If it is still off-hook then a check is made at 640 to determine if the E-lead detect signal is on-hook. If it is on-hook, then the calling party has hung up, and the control circuit 450 sets the "Loop Status" 475 inactive at 645, signalling the call processor 435 that the call is terminated. The call processor 435 may in turn signal CPU 495 that the call is terminated. Control circuit 450 then waits as shown at reference 650 for the "DID Received" signal 480 to become inactive, signifying that the CPU 495 is completed with the call and is ready to accept a new call. When the "DID Received" signal 480 goes inactive, control passes to step 675 where the M-Lead is placed on hook. Control then returns to step 600 where the control circuit 450 restarts it's sequence at reference 600. Returning again to reference 635, if the On/off-hook control signal 485 were found to be on-hook, then a 1.5 second timer is started as shown at reference 655. This timer is used to distinguish between a `hookflash` signal, which is typically less than 1.5 seconds, and an on hook command which should be at least 1.5 seconds. At 660, the control circuit 450 causes the M-Lead relay 455 to place the M-Lead on-hook. At 665 a check is made to determine if the 1.5 second timer has expired. If it has expired, then the signal was a true on-hook command, and control passes to reference 645 for the termination of the call. If at 665 it is determined that the 1.5 second timer has not expired, then a check is made at 670 to determine if the on/off-hook control 485 is still on-hook. If it is still on-hook then the timer is tested again at 665. If the on/off-hook control 485 is off-hook again, then the command was a flash, and control returns to reference 630, where the M-Lead is taken off-hook once more.
A diagram of the Subscriber Master Record, reference 700, is illustrated in FIG. 7. The subscriber master record contains information regarding a given subscriber's chosen method of call handling. This information is used by the Telephone Control System 1 to determine how to process the call. One unique subscriber master record exists for each subscriber to the Telephone Control System 1. All subscriber master records are stored in disk 505 and, upon initialization of the Telephone Control System 1, are copied to a common database in RAM memory 500 by CPU 495. This facilitates fast retrieval of this information, which is necessary for the real-time processing of calls to the access control system 1.
Still referring to FIG. 7, the subscriber master record 700 contains as it's first element an access (DID) number, shown at reference 701. As described earlier, this access number 701 is the unique phone number which is used to reach a given subscriber via the Public Switched Telephone Network 2. A PIN code, which is used by the subscriber to identify himself to the Telephone Control System 1, is shown at 702. At 703, a call handling mode is shown. The call handling mode defines the basic method of call handling which has been chosen by the subscriber. Possible call handling modes include direct forwarding, announced forwarding, message center, voice screen forwarding, urgent screen forwarding, VIP code screen forwarding, and branch-routing. At 704, a standard greeting type is shown. The standard greeting type, 704, defines the courtesy greeting announcement which the subscriber has selected for the Telephone Control System 1 to use when first answering a call. At 705, an options field is shown. This options field is used to contain several miscellaneous option flags which may be used to modify the operation of the basic call handling mode. Options 705 include `page option` which causes a page to be sent when a call is forwarded, an `emergency/urgent` option which modifies the operation of the priority or urgent screen forwarding mode, a `busy/no-answer` option which causes calls to be sent to the message center if a busy or no-answer condition is detected, and a voice screen hold off option which modifies the operation of the voice screen forwarding mode. A transfer message type is shown at reference 706. The transfer message type, 706, defines the courtesy announcement which the subscriber has selected for the access control system 1 to use as a call is being transferred. A transfer number is shown at 707. This is the number which the access control system 1 will use when forwarding, or transferring calls for this subscriber. At 708 an extension number is shown which may be used by the Telephone Control System 1 to announce to a caller the extension number of the phone at which the subscriber is located. The subscriber's message center number is shown stored at 709. The subscriber's pager number is shown stored at 710. The subscriber's office number is shown stored at 711. The subscriber's home number is shown stored at 712. The subscriber's mobile phone number is shown stored at 713. At 714 a VIP screen code is shown. The VIP screen code is a code which may be used by a caller to cause his call to be forwarded to the subscriber, when the subscriber has selected VIP code screened forwarding mode. The number of the current feature memory which is being used is shown stored at 715. At 716 a pager message display number is shown. This is the number which the subscriber wishes to appear in the display of his pager when the access control system 1 has taken a message from a caller. At 717 a pager forwarding display number is shown. This is the number which the subscriber wishes to appear in the display of his pager when the Telephone Control System 1 is in the process of forwarding a call to the subscriber. At 718 a communicator dynamic mode display number is shown. This is the number which the subscriber wishes to appear in the display of his communicator 11 when the Telephone Control System 1 has a call holding, and requires that the subscriber select a method of call handling to dispose of the call. The time and date that the last caller abandoned a meet-me call by hanging up without leaving a message is shown stored at 719. The time and date that the last caller abandoned a meet-me call by leaving a message is shown stored at 720. A count of the number of calls which have been transferred to an external message center by the Telephone Control System 1 is shown stored at 721. Shown generally at 722 are the branch routing numbers 0 through 9. These fields contain the phone numbers to which a call should be transferred if a caller touches one of the digits 0 to 9 when the access control system 1 is processing a call using branch-routing mode. The branch-routing default transfer number is shown stored at 723. This is the number to which the call is transferred should a caller not enter one of the digits 0 to 9. Shown stored at 724 is the feature timer duration. This value determines when the feature timer expires. Shown stored at 725 is the feature timer termination mode. This field contains the mode memory which the subscriber wishes to use upon expiration of the feature timer. The fields necessary to implement the weekly schedule function are shown generally at reference 726. In the preferred embodiment the weekly schedule may contain up to 32 events (steps). For each step, the subscriber master record 700 stores a time and date, and a mode memory number to be used at that time and date. The current step number (1 to 32) is shown stored at 727. A flag which indicates to Telephone Control System 1 that the weekly schedule is on, is shown stored at 728. A flag which informs the Telephone Control System 1 as to whether the subscriber is allowed to make multiple outside calls is shown stored at 729. A flag indicating that the subscriber has selected to use his communicator 11 in the `dynamic mode assignment` mode is shown stored at 730. A count of the number of calls made to this ACCESS NUMBER is shown stored at 731.
A diagram of a Mode Memory, reference 800, is illustrated in FIG. 8. As described previously, the mode memories are used by subscribers of the Telephone Control System 1 to store their commonly used call handling modes and options. As with the subscriber master records 700, the mode memories 800 are stored in disk 505 and, upon initialization of the Telephone Control System 1, are copied to a common database in RAM memory 500 by CPU 495. Each mode memory is unique to an individual subscriber, and is identified by storing the subscriber's ACCESS NUMBER as part of the mode memory, as shown at reference 801. In the preferred embodiment, the subscriber may have up to 90 mode memories, Each mode memory is identified by a unique mode memory number, 10 through 99. This mode memory number is shown stored as part of the mode memory 800 at reference 802. Shown generally at reference 803, are the various fields which the subscriber has selected to store in the mode memory 800. As can be seen, these are a subset of the fields which are stored in the subscriber master record 700. To invoke a mode memory, the Telephone Control System 1 need only copy the fields from the mode memory 800 to the corresponding fields in the subscriber master record 700. The access control system 1 also copies the mode memory number 802 to the current feature memory field 715 of the subscriber master record 700.
A flowchart of the Main Task for the Call Processing Facility (CPF) 100 is shown in FIG. 9. This flowchart represents the instructions, or steps, followed by CPU 495, as it controls functions of CPF 100. The starting point for the CPF--MAIN TASK is shown at reference 900. At step 901 the CPU 495 performs initialization processes. These processes are well known in the art and include such activities as using a boot PROM to load the operational program from disk, checking for memory errors, performing hardware diagnostics, etc. The subscriber master records 700 are read from disk 505 and copied to a database in memory 500, as shown at step 902. In a similar manner, the mode memories 800 are read from disk and copied to a database in memory, as shown at step 903. At step 904, the multitasking processes are established. The multitasking allows the software to perform more than one process simultaneously. Multitasking techniques are well known in the art. As an example, UNIX is a widely used multitasking operating system. Other well known techniques allow a pseudo-multitasking function to be accomplished on a non-UNIX based operating system by constructing a `round-robin` scheduler, by which a main process allocates `time slices` to each of a number of sub-processes. At step 905 a process for the Network Message Task is initialized, and at step 906 control is passed to the CPF--Network Message Task. At step 907 a process for the Call Handler Task for the first trunk 3 is initialized, and at step 908 control is passed to the CPF--Call Handler Task. In a similar fashion, at step 909 a process for the Call Handler Task for the last trunk 3 is initialized, and at step 910 control is passed to the CPF--Call Handler Task. At step 911 a process for the Call Termination Task is initialized, and at step 912 control is passed to the CPF--Call Termination Task.
A flowchart of the CPF--Network Message Task is illustrated in FIG. 10. The function of this task is to receive and process messages received by Data Network Interface 510 from other facilities of the access control system 1. The CPF--Network Message Task is entered at step 1000. At step 1001 a determination is made as to whether a "request master record" message has been received. If this message has been received, then at step 1002 the subscriber master record 700 which corresponds the DID number, ANI number, or PIN code provided in the message is searched for in the database of memory 500. Upon finding this subscriber master record, at step 1003 a message containing a copy of this subscriber master record is sent back to the requesting facility via data network interface 510. Control then returns to step 1000. Should it be determined at step 1001, that no "request master record" message has been received, then at step 1004 a check is made to determine if an "update master record" message has been received. If such a message has been received, then at step 1005 a master record for a subscriber is recovered from the message and copied to the the subscriber's master record 700, at which point control returns to step 1000. If an "update master record" message is not detected at step 1004, then at step 1006 a check is made to determine if a "clear dynamic mode assignment flag" message has been received. If such a message has been received, and the message identifies a specific subscriber DID number, then the dynamic mode assignment flag 730 in the subscriber master record 700 for this subscriber is cleared at step 1007, and control returns to step 1000. If a "clear dynamic mode assignment flag" message is not detected at step 1006, then at step 1008 a check is made to determine if a "set dynamic mode assignment flag" message has been received. If such a message has been received, and the message identifies a specific subscriber DID number, then the dynamic mode assignment flag 730 in the subscriber master record 700 for this subscriber is set at step 1009, and control passes to step 1000. If a "set dynamic mode assignment flag" message is not detected at step 1008, then at step 1010 a check is made to determine if "change to new mode memory" message has been received. If such a message has not been received, then control passes to step 1014. If such a message has been received, and the message identifies a specific subscriber DID number, then at step 1011 a check is made to determine if the message was sent by the Communicator Access Facility (CAF) 125. If the message was not from the CAF 125, then control passes to step 1013. If the message was from the CAF 125, then at step 1012 an indication is sent to the CPF--Dynamic Mode Assignment routine (shown in FIG. 13), that this message was received, and control passes to step 1013. At step 1013, the mode memory number and the subscriber's DID number are removed from the message, and the corresponding mode memory 800 is copied to the corresponding subscriber's subscriber master record 700. Control then returns to step 1000. If at step 1010 it is determined that a `change to new mode memory message` is not received, then control passes to step 1014, where a determination is made as to whether a `mode memory inquiry` message is received, and if this is the case then control passes to step 1015 where the mode memory 800 identified in the message for the subscriber identified in the message is retrieved from the database of memory 500 and a message is constructed and sent back to the requesting facility via data network interface 510. Control then returns to step 1001. If at step 1014 it is determined that a `mode memory inquiry` message is not received, then control passes to step 1016, where a determination is made as to whether a `mode memory update` message is received, and if this is the case, then control passes to step 1017 where the new mode memory contents are retrieved from the message, and the mode memory is copied to the appropriate mode memory 800 in the database of memory 500. Control then returns to step 1001. If at step 1016, it is determined that a `mode memory update` message is not received, then control passes to step 1018 where a determination is made as to whether a `create new subscriber` message is received, and if this is the case then control passes to step 1019 where the DID number is retrieved from the message, a subscriber master record 700 is created for this DID number 701, and a set of mode memories 800 are created for this DID number 701. Control then returns to step 1001. If at step 1018 it is determined that a `create master record` message is not received, then control returns to step 1001.
A flowchart of the CPF--Call Termination Task is illustrated in FIG. 11. The purpose of this task is to monitor the loop status signal 475 for each trunk interface 400, and to terminate any call in progress should the loop status become inactive. In this way the system detects if the calling party has hung up. The CPF--Call Termination Task is entered at step 1100. At step 1101 a trunk pointer is set to a value of 1. At step 1102 the loop status signal 475 for the trunk pointed to by the trunk pointer is read via call processor 435. At step 1103, a determination is made as to whether the loop status signal 475 is active. If the signal is active, then control passes to step 1106. If the signal is not active, then the caller must have hung up, and at step 1104 the trunk is placed on hook by call processor 435 via on/off hook control signal 485. Then at step 1108 a determination is made as to whether this trunk was processing the "CPF--Meet Me Caller" function, and if this is the case then control passes to step 1109 where the current time and date is stored in the "last meet-me abandon" field 719 of the subscriber master record 700. Control then passes to step 1105. Control also passes to step 1105 if at step 1108 it is determined that the trunk was not processing the "CPF--Meet Me Caller" function. At step 1105 the CPU 495 signals the multitasking process 907 controlling the call handler task for this trunk to return to it's entry point 908, thereby terminating any activity on that trunk. Control then passes to step 1106, where a check is made to determine if the trunk pointer is pointing to the last trunk. If the trunk pointer is pointing to the last trunk, then control returns to step 1101. If the trunk pointer is not pointing to the last trunk, then at step 1107 the trunk pointer is incremented and control returns to step 1102.
A flowchart of the CPF--Call Handler Task is illustrated in FIGS. 12a and 12b. The function of this task is to respond to an incoming call on a trunk 3, receive the DID digits identifying the subscriber's ACCESS NUMBER being dialed, determine the method of call handling as specified in the database of memory 500 by subscriber master record 700 which corresponds to that ACCESS NUMBER, and then cause the call to be processed accordingly. The CPF--Call Handler Task is entered at step 1200, a connection point labelled "CPF IDLE" is passed at reference 1201, and at step 1202 the DID received signal 480 is cleared, allowing trunk interface 400 to receive a new call. Control then remains at step 1203 until an incoming call signal 470 is received from the trunk interface 400, at which point control passes to step 1204 causing the call processor to issue an off hook signal via it's on/off hook control line 485. Then at step 1205, incoming DID digits are decoded and accepted by the DTMF detector of call processor 435. Then at step 1206, after the DID digits have been received, the DID received signal 480 is set, causing E & M control circuit 450 to force the M-Lead active, thereby seizing the trunk. Control then passes through a connection point labelled "CPF VIRTUAL TRANSFER" at reference 1207. At step 1208 the subscriber master record 700 which corresponds to the received DID number is retrieved from the database of memory 500. At step 1209 the call count 731 is incremented in the subscriber master record 700. At step 1210 a check is made to determine if the feature timer is active. This is accomplished by checking the feature timer duration 724. The feature timer is active if the feature timer duration 724 is non zero. If the feature timer is not active, then control passes to step 1213. If the feature is active, then another check is made at step 1211 to determine if the feature timer has expired since the last call. This is determined by comparing the feature timer duration 724 with the current time and date maintained by CPU 495. The feature timer has expired if the feature timer duration 724 does not extend beyond the current time and date. If the feature timer has not expired, then control passes to step 1213. If the feature timer has expired, then at step 1212 the mode memory 800 specified by the feature timer termination mode 725 is copied to the subscriber master record 800, and the feature timer duration 724 is cleared to zero. Control then passes to step 1213. A determination is made at step 1213 as to whether the weekly schedule is active by checking the status of the weekly schedule active flag 728. If the weekly schedule is not active, then control passes to step 1217. If the weekly schedule is active, then a determination is made a step 1214 as to whether the current step of the weekly schedule is correct. This is accomplished by finding the current step of weekly schedule 726 as pointed to by the weekly schedule current step 727, and comparing the time and date of the next step with the current time and date. If the current time and date fall between the current step and the next step, then the current step is correct. If, by this process, it is determined that the current step is correct, then control passes to step 1217. Otherwise, at step 1215, the weekly schedule current step 727 is incremented to point to the next step. Then at step 1216, the mode memory number corresponding to the new step of the weekly schedule 726 is found, the corresponding mode memory 800 is copied to the subscriber master record 700, and then control passes to step 1217. At step 1217 the status of the dynamic mode assignment flag 730 is checked, and if it is found to be active, control is passed at step 1218 to the CPF--Dynamic Mode Assignment. Otherwise, control passes through a connector labelled "CPF MODE" at reference 1219, and then passes to step 1220. At step 1220 a determination is made as to whether the current call handling mode 703 is set for `direct forwarding`, and if so control is passed via step 1221 to the CPF--Direct Forwarding. Otherwise a determination is made at step 1222 as to whether the current call handling mode 703 is set for `announced forwarding` and if not control passes to step 1230. If the call handling for 703 is set for `announced forwarding`, then at step 1223 a further check is made to determine if the transfer number 707 is set for meet-me, and if not control passes to step 1230. If the transfer number 707 is set for meet-me, then at step 1224 one audible ring is played to the caller by call processor 435. Then at step 1225, the `pager display digits` are set to be equal to the DID number, prior to the "send page" subroutine being called at step 1226. Upon receiving a page with his own DID number in the display, the subscriber may recognize this is a meet-me call. Then a 4 second delay is initiated at step 1227, another ring is generated at step 1228, and another 4 second delay is initiated at step 1229, before passing control to step 1230. As can be seen, the effect of steps 1224 to 1229 is to simulate the typical ringing cadence expected by a caller, and in addition allow some time for the page sent at step 1225 to reach the subscriber's pager. Because the caller must wait for the subscriber to get to a phone when the subscriber is using meet-me, the sequence of steps 1224 to 1229 has the effect of reducing the delay perceived by the caller. At step 1230, an audible ring is generated towards the caller by call processor 435. Then at step 1231 a determination is made as to whether the caller has entered the PIN code 702. If the PIN code has been entered, then the caller must be the subscriber, and therefore control passes to the CPF--Command Mode via step 1233. If the PIN code has not been entered, then the control passes to step 1270 where a determination is made as to whether the `message center access code` has been entered by the caller. In the preferred embodiment the `message center access code` consists of the digits "*9" and is the same for all subscribers. This code may be used by callers who simply wish to leave a message and do not need to speak with the subscriber. If the `message center access code` has been entered by the caller, then control passes to the "CPF--Caller Message Center" function as shown at step 1271. If the `message center access code` has not been entered, then control passes to connector label "CPF GREETING" as shown at reference 1232.
Still referring to FIGS. 12a and 12b, control passes through the connector labelled "CPF GREETING" at reference 1233 to step 1234, where a determination is made as to whether the call handling mode 703 is set for `branch-routing`, and if so control passes through a connector labelled "CPF PIN" at reference 1235. Otherwise, at step 1236 the standard greeting type 704 is retrieved from the subscriber master record 700. If the standard greeting type is `stock` as determined at step 1237, then control passes to step 1238 where a stock generic greeting is played to the caller: "Hello, you have reached your party's telephone control system." Control then passes through a connector labelled "CPF PIN" at reference 1239. If the standard greeting type is not determined to be `stock` at step 1237, then a further check is made at step 1240 to determine if the standard greeting type is `drop-in`, and if not the control is passed to step 1245. If the standard greeting type is `drop-in` then at step 1241 the subscriber's prerecorded drop-in name is retrieved from disk 505. Then at step 1242 the call processor 435 plays the greeting: "Hello, you have reach the telephone control system for . . . ", and then at step 1243 completes the greeting by playing back the pre-recorded name of the subscriber retrieved form disk in step 1241. Control then passes through a connector labelled "CPF PIN" at 1244. As was described earlier, if the standard greeting type was found not to be `drop-in` at step 1240 then control passed to step 1245. At step 1245, a check is made to determine if the standard greeting type is `personalized`, and if not control passes to step 1238, described earlier. Otherwise, control passes to step 1246 where the subscriber's pre-recorded personalized greeting is retrieved from disk 505, and is then played back to the caller at step 1247 by call processor 435. Control then passes through connector labelled "CPF PIN" at reference 1248 and a check is made at step 1249 to determine if the caller has entered a PIN code. If the PIN code has been entered, then the caller must be the subscriber, and therefore control passes to the CPF--Command Mode via step 1250. If the PIN code has not been entered, then the control passes to step 1272 where a determination is made as to whether the `message center access code` has been entered by the caller. As was described earlier, in the preferred embodiment the `message center access code` consists of the digits "*9" and is the same for all subscribers. This code may be used by callers who simply wish to leave a message and do not need to speak with the subscriber. If the `message center access code` has been entered by the caller, then control passes to the "CPF--Caller Message Center" function as shown at step 1273. If the `message center access code` has not been entered, then control passes to step 1251, where the call handling mode 703 is retrieved from the subscriber master record 700. Then at step 1252 a check is made to determine if the call handling mode 703 is set for `announced forwarding`, and if so a further check is made at step 1253 to determine if the transfer number 707 is set for meet-me. If the transfer number is not set for meet-me then control passes to CPF--Announced Forwarding via step 1254. If the transfer number is set for meet-me, then control passes to CPF--Meet-Me Caller via step 1255. If at step 1252 it was determined that the call handling mode was not set for `announced forwarding`, then control passes to step 1256. At step 1256 a check is made to determine if the call handling mode 703 is set for `urgent screen forwarding`, and if so control passes to CPF--Urgent Screen via step 1257. Otherwise, at step 1258 a check is made to determine if the call handling mode 703 is set for `VIP code screen forwarding`, and if so control passes to CPF--VIP Code Screen via step 1259. Otherwise, at step 1260 a check is made to determine if the call handling mode 703 is set for `voice screen forwarding`, and if so control passes to CPF--Voice Screen via step 1261. Otherwise, at step 1262 a check is made to determine if the call handling mode 703 is set for `branch-routing`, and if so control passes to CPF--Branch-Routing via step 1263. Otherwise control passes to CPF--Message Center via step 1264.
A flowchart of the CPF--Dynamic Mode Assignment is illustrated in FIG. 13. The purpose of this function is to process calls for a subscriber who is using a Communicator 11, and who has selected the dynamic mode assignment mode of operation. The dynamic mode assignment mode of operation allows a subscriber to chose dynamically, with each incoming call, the call handling mode to be used for the call. The subscriber is alerted via his Communicator 11 that an incoming call is present, and the subscriber may then transmit a `new mode memory` message from his Communicator 11 thereby informing the Telephone Control System 1 as to how the call should be handled. The CPF--Dynamic Mode Assignment function is entered at step 1300, and at step 1301 the `pager display digits` are set equal to the communicator dynamic mode display number 718. At step 1302, the `send page` subroutine is called, causing a page to be sent to the subscriber's Communicator 11. At step 1303, a ring count is set to a value of 4. At step 1304 an audible ring is played to the caller by call processor 435, and at step 1313 a determination is made as to whether the caller has entered the PIN code 702. If the PIN code has been entered, then the caller must be the subscriber, and therefore control passes to the CPF--Command Mode via step 1314. If the PIN code has not been entered, then the control passes to step 1315 where a determination is made as to whether the `message center access code` has been entered by the caller. As was described earlier, in the preferred embodiment the `message center access code` consists of the digits "*9" and is the same for all subscribers. This code may be used by callers who simply wish to leave a message and do not need to speak with the subscriber. If the `message center access code` has been entered by the caller, then control passes to the "CPF--Caller Message Center" function as shown at step 1316. If the `message center access code` has not been entered, then at step 1305 a 4 second delay is initiated, thus creating a typical ring cadence. At step 1306 a check is made to determine if the Network Message Task (FIG. 10) has received a `new mode memory` message from the Communicator 11 belonging to this subscriber. If such a message has been received, then the control passes to connector labelled "CPF MODE" as indicated at reference 1307. If message was not received, then the ring count is decremented at step 1308, and at step 1309 a check is made to determine if the ring count is 0. If the ring count is not '0, then control returns to step 1304 and the ring cycle is repeated. If the ring count is 0, indicating four rings cycles have been generated without the subscriber responding, then control passes to step 1310, labelled "CPF SORRY" by the connector at reference 1311, and the caller is informed, via call processor 435: "I'm sorry, your party is not available at the moment. We will connect you to your party's message center where you may leave a detailed message." Control then passes to CPF--Caller Message Center via step 1312.
A flowchart of the CPF--Direct Forwarding function is illustrated in FIGS. 14 and 14a. The purpose of this function is to process calls for a subscriber who has selected the `direct forwarding` call handling mode. In this mode, calls are transferred without any announcement. Low amplitude `confidence tones` are generated just prior to the transfer so that the subscriber may have an opportunity to enter his PIN Code. The CPF--Direct Forwarding function is entered at step 1400, and `confidence tones` are generated at step 1401 by call processor 435. The `confidence tones` are a prerecorded sequence of tones which are designed to sound similar to the interoffice multifrequency signalling tones that callers are familiar with. In this way the caller has no clear indication that the call is being answered and transferred, and yet at the same time the subscriber is given an indication as to when he may enter his PIN Code. At step 1402, a determination is made as to whether the subscriber has entered his PIN code. If the PIN code has been entered, then control passes to CPF--Command Mode via step 1403. Otherwise control passes to step 1416 where a determination is made as to whether the `message center access code` has been entered by the caller. As was described earlier, in the preferred embodiment the `message center access code` consists of the digits "*9" and is the same for all subscribers. This code may be used by callers who simply wish to leave a message and do not need to speak with the subscriber. If the `message center access code` has been entered by the caller, then control passes to the "CPF--Caller Message Center" function as shown at step 1417. If the `message center access code` has not been entered, then control passes to a connector labelled "CPF DIAL TRANSFER" at reference 1404 to step 1405, where a check is made to determine if the transfer number 707 contains a reference to a reserved phone number (a tag) or a reference to a mode memory. Tags may be used as follows:
______________________________________TAG DIGIT RESERVED PHONE NUMBER______________________________________1 message center number 7092 pager number 7103 office number 7114 home number 7125 mobile phone number 7136 meet-me tag7 `externally entered` number______________________________________
As will be described in more detail later in this discussion, if a mode memory 800 has a transfer number 707 that is an `externally entered` number tag, then when that mode memory is invoked, the transfer number is not changed from the previous value. Also, if a mode memory which contains a transfer number 707 that is an `externally entered` number tag can be invoked remotely by the subscriber via a Feature Group D trunk, causing the ANI number received by the trunk to be used as the transfer number 707. The reference to the mode memory may be in the form of the two digit mode memory number 10-99. Therefore, at step 1405, if the transfer number 707 contains the digits 1 through 6, or the digits 10 through 99, then control will pass to step 1406. Otherwise, control will pass to step 1409. At step 1406 a determination is made as to whether the transfer number 707 contains the meet-me tag (i.e. digit 6). If the meet-me tag is round, then control passes to the CPF--Meet-Me Caller Function via step 1407. If the meet-me tag is not found at step 1406, then control passes to step 1408, where the tag or mode memory is expanded to a real phone number which can be dialed. If the transfer number 707 contains a tag, then the corresponding reserved phone number per the table above is used as the expanded number to be dialed. If the transfer number 707 contained a mode memory number, then the transfer number 707 from the corresponding mode memory 800 is used as the expanded number to be dialed. Control then passes to step 1409, where a determination is made as to whether the transfer number to be dialed can be found as the ACCESS NUMBER 801 in any of the subscriber master records 700. If so, then it is not necessary to do a physical transfer, and the call can be continued on the same trunk by passing control through the connector labelled "CPF VIRTUAL TRANSFER" at reference 1410. Otherwise, at step 1411 a flash is generated by call processor 435 by producing a 700 millisecond on hook signal on the on/off hook control line 485. This flash places the calling party on hold and causes a second dial tone to be returned on trunk 3 by the serving central office of the PSTN 2. At step 1412 a brief pause is introduced to allow time for the dial tone to appear on the trunk, and then at step 1413 the transfer number is dialed via the DTMF generator of call processor 435. Then at step 1418 the `busy/no-answer` option flag of options 705 of subscriber master record 700 is checked. The function of this option is to handle calls which are being sent to a subscriber even if the subscriber's line is busy or does not answer. If this option is active then at step 1419 a flash is generated by call processor 435 causing the calling party to be taken off hold and connected to the call being placed to the transfer number. The calling party will thus be able to heart he progress of the call and will therefore hear the subscriber answer if the subscriber does indeed answer. At step 1420 a determination is made as to whether the call was local or long distance. If the transfer number was longer than 7 digits, or if the 7 digit number contained a prefix which is long distance in this area, then the call was long distance and a 40 second timer is started at step 1422. If the transfer number was less than or equal to 7 digits, then the call was local and a 25 second timer is started at step 1421. Then at step 1423 a determination is made as to whether precision busy/ring detector 437 is detecting busy signal, and if not control passes to step 1424. If a busy signal is detected at step 1423, indicating that the subscriber's line is busy, then control passes to step 1429 where a flash is generated by call processor 435 causing the call attempt to be dropped but leaving the calling party connected to the telephone control system 1. Control then passes to a connector labelled "CPF--Sorry" as shown at step 1430, which causes the caller to be sent to the subscriber's message center function. If at step 1423 a busy signal was not detected, then control passes to step 1424 where a determination is made as to whether the timer has expired. If the timer has expired, indicating that neither busy or ringing where detected, then control passes to 1414. If at step 1424 it is determined that the timer has not expired, then control passes to step 1425 where a determination is made as to whether precision busy/ring detector 437 is detecting a first ringing signal, and if not control returns to step 1423. If the first ringing signal is detected at step 1426, then control passes to step 1426, where a determination is made as to whether this is the fourth ring signal, and if so, indicating that the subscriber is not answering the call, then control passes to step 1429 causing the caller to be ultimately routed to the subscriber's message center function as was described earlier. If at step 1426 it is determined that this is not the fourth ring, then control passes to step 1427 where control idles until an end-of-ring is detected by precision busy/ring detector 437. Control then passes to step 1428 where a 6 second `inter-ring timer` is started. Control then passes to step 1431 where a determination is made as to whether precision busy/ring detector 437 is detecting ringing signal and if so control returns to step 1426. If however at step 1431 it is determined that ringing signal is not being detected, then control passes to step 1432 where the `inter-ring timer` is checked. If the `inter-ring timer` has not expired then control returns to step 1431. If the `inter-ring timer` has expired, indicating the subscriber has answered the call, then control passes to step 1414. At step 1414 an on hook signal is generated on the on/off hook control line 485, causing the call to be transferred to the dialed number, and freeing up the trunk 3 to handle another incoming call. control then passes to the connector labelled "CPF IDLE" at reference 1415.
A flowchart of the CPF--Announced Forwarding function is illustrated in FIGS. 15a and 15b. The purpose of this function is to process calls for a subscriber who has selected the `announced forwarding` call handling mode. In this mode, callers are greeted with a brief courtesy announcement prior to being transferred. In addition, if a `page option` has been selected, then a page is sent to the subscriber's pager prior to transferring the call. The CPF--Announced Forwarding function is entered at step 1500 and at step 1501, a determination is made as to whether the page flag of options 705 is set, and if it is not set, then control passes to the connector labelled "CPF AF2" at reference 1502. If the page flag is set, the control passes to step 1503 where the display digits are set equal to the pager forwarding display number 717. At step 1504 the `send page` subroutine is called causing a page to be sent to the subscriber's pager. Then at step 1505, the call processor 435 plays to the caller the message: "We are sending a page to inform your party of your call. Please stay on the line." At step 1506 a delay is initiated to allow the pager sufficient time to receive the page. Then at step 1507, another message is played to the subscriber: "We have sent a page to your party and we will connect your call momentarily. Please stay on the line." At step 1508 an additional delay is initiated to allow the subscriber the opportunity to get to a phone. Control then passes to the connector labelled "CPF AF2" at reference 1509. The connector labelled "CPF AF2" at reference 1510 passes control to step 1511, where the transfer message type 706 is retrieved from subscriber master record 700. Then at step 1512, a check is made as to whether the transfer message type is `0`. If the transfer message type is `0`, indicating no transfer message is to be played, then control passes to the connector labelled "CPF DIAL TRANSFER" at reference 1520. If the transfer message type is not `0`, then control passes to step 1513 where a check is made to determine if the transfer message type is `1`. If the transfer message type is `1`, then at step 1514 the call processor 435 plays to the caller the message: "We're connecting your call", and then control passes to the connector labelled "CPF DIAL TRANSFER" at reference 1520. If the transfer message-type is not `1`, then control passes to step 1515 where a check is made to determine if the transfer message type is `2`. If the transfer message type is `2`, then at step 1516 the call processor 435 plays to the caller the message: "We're connecting your call. When the call is answered, please ask for your party by name", and then control passes to the connector labelled "CPF DIAL TRANSFER" at reference 1520. If the transfer message type is not `2`, then control passes to step 1517 where a check is made to determine if the transfer message type is `3`. If the transfer message type is `3`, then at step 1518 the call processor 435 plays to the caller the message: "We're connecting your call. When the call is answered, please ask for extension number . . . " Then at step 1519, the extension number 708 is retrieved from the subscriber master record 700 and is voiced to the caller by call processor 435. Control then passes to the connector labelled "CPF DIAL TRANSFER" at reference 1520.
A flowchart of the CPF--Urgent Screen function is illustrated in FIG. 16. The purpose of this function is to process calls for a subscriber who has selected the "priority screen" or `urgent screen` call handling mode. The CPF--Priority/Urgent Screen function is entered at step 1600, and control passes to step 1601, where call processor 435 plays to the caller the message: "Your party is not readily available at the moment. If this call is . . . " Control then passes to step 1602 where the urgent/emergency flag of the options 705 is checked. If the flag is set for `urgent`, then the call processor 435 plays to the caller " . . . urgent . . . ", and if the flag is set for emergency then call processor 435 plays to the caller " . . . an emergency . . . " Control then passes to step 1603 where the call processor completes the sentence by playing the message " . . . then touch 0 now and we will attempt to connect your call. Otherwise, we will connect you to your party's message center where you may leave a detailed message." Then at step 1604, a 5 second timer is started. At step 1605 a determination is made as to whether the caller has touched 0. If the caller has touched 0, then control passes. to the CPF--Announced Forwarding function via step 1606. If the caller has not touched 0, then at step 1607 a determination is made as to whether the 5 second timer has expired. If the 5 second timer has not expired then control returns to step 1605. If the 5 second timer has expired, then at step 1608 the caller is informed: "Please standby". Control then passes to the CPF--Caller Message Center function via step 1609.
A flowchart of the CPF--VIP Code Screen function is illustrated in FIG. 17. The purpose of this function is to process calls for a subscriber who has selected the `VIP code screen` call handling mode. The CPF--VIP Code Screen function is entered at step 1700 and control is passed to step 1701 where the call processor 435 plays to the caller the message: "Your party is not readily available at the moment. Please enter your code now, or we will connect you to your party's message center where you may leave a detailed message." Control then passes to step 1702 where a 5 second timer is started. At step 1703 a determination is made as to whether the caller has entered the VIP screen code 714 as stored in the subscriber master record 700. If the caller has entered the correct VIP screen code, then control passes to the CPF--Announced Forwarding function via step 1704. If the caller has not entered the VIP screen code 714, then at step 1705 a determination is made as to whether the 5 second timer has expired. If the 5 second timer has not expired then control returns to step 1703. If the 5 second timer has expired, then at step 1706 the caller is informed: "Please standby". Control then passes to the CPF--Caller Message Center function via step 1707.
A flowchart of the CPF--Branch Routing function is illustrated in FIG. 18. The purpose of this function is to process calls for a subscriber who has selected the `branch-routing` call handling mode. The CPF--Branch Routing function is entered at step 1800, and control passes to step 1801 where the prerecorded branch-routing greeting is retrieved from disk 505. Then at step 1802, the playback to the caller of the branch-routing greeting is begun by call processor 435. At step 1803 a determination is made as to whether the caller has entered a digit. If the caller has not entered a digit then at step 1804 a determination is made as to whether the call processor 435 has completed the playback of the branch-routing greeting, and if an additional 5 seconds have expired. If this is the case then control passes to step 1805. If this is not the case, then control returns to step 1803. If at step 1803 it is determined that the caller has entered a digit, then control passes to step 1806 where a determination is made as to whether there exists a branch-routing number 722 in the subscriber master record 700 which corresponds to the digit entered by the caller. For example, if the subscriber entered digit 4, then a determination is made as to whether the subscriber master record holds a phone number entry in the branch routing number 4 position at 722. If an entry is found in such a manner, then control passes to step 1807. Otherwise, control passes to step 1805 where a the branch routing default number 723 is retrieved for the subscriber master record 700, and is set up to be used as the transfer number for this call. Control then passes to the connector labelled "CPF DIAL TRANSFER" at reference 1808. Should the caller have entered a digit which corresponded to a branch routing number 722, then at step 1807 the corresponding branch routing number 722 is retrieved form the subscriber master record 700, and is setup to be used as the transfer number for this call. Control then passes to the connector labelled "CPF DIAL TRANSFER" at reference 1808.
A flowchart of the CPF--Caller Message Center function is illustrated in FIG. 19. The purpose of this function is to process calls for a subscriber who has selected the `message center` call handling mode. The CPF--Caller Message Center function is entered at step 1900 and control passes to step 1901 where a determination is made as to whether an external message center has been selected. This determination is made by examining the message center number 709 in the subscriber master record 700. If the message center number 709 contains a phone number, then external has been selected. If the message center number 709 does not contain a phone number, then internal message center has been selected. The subscriber may chose an external voice mail system, an answering service, his secretary, or any other appropriate phone number for the external message center number 709. If, at step 1901, it is determined that the subscriber has selected the internal message center, then control passes to step 1902, where the caller is prompted: "Please leave your message at the tone . . . BEEP." Then at step 1903 the callers message is recorded by call processor 435 and stored on disk 505. At step 1904 a determination is made as to whether the caller has completed leaving the message. This is accomplished by call processor 435 determining if there has been at least 3 seconds of silence on the line since the last sound. If the caller has not completed leaving a message then the recording continues at step 1903. If the caller has completed leaving a message, then control passes to step 1905, where the caller is prompted: "Thank you for calling. Good-bye." Then at step 1906 the trunk is placed on hook by call processor 435 via on/off hook control signal 485. Control then passes to step 1907, where a decision is made as to whether a message was actually left. A message is determined to be left if at least 3 seconds of non-silence has been recorded, as determined by call processor 435. If a message was not left, then control passes to connector labelled "CPF IDLE" at reference 1908. If a message was left by the caller, then control passes to step 1909, where the `display digits` are set equal to the pager message center display number. The `send page` subroutine is then called at step 1910, and control passes to a connector labelled "CPF IDLE" at reference 1911. Returning now to step 1901, if a determination is made, in the manner described above, that an external message center is selected, then control passes to step 1912 where the party is informed by call processor 435: "Please standby," then control passes to step 193 where a flash is generated by call processor 435 by producing a 700 millisecond on hook signal on the on/off hook control line 485. This flash places the calling party on hold and causes a second dial tone to be returned on trunk 3 by the serving central office of the PSTN 2. At step 1914 a brief pause is introduced to allow time for the dial tone to appear on the trunk, and then at step 1915 the message center number 709 is dialed via the DTMF generator of call processor 435. The message center number may contain special dialing characters, including characters for pausing, waiting for tones, and waiting for answer. Thus a sequence of dialing characters may be constructed to allow the Telephone Control System 1 to transfer calls to a voice mail system requiring the entry of a subscriber ID. For example, an external message center dialing sequence for a typical voice mail system may be: 7 digit phone number of voice mail system+Wait for answer+4 digit voice mail subscriber ID. Continuing now, at step 1916 an on hook signal is generated on the on/off hook control line 485, causing the call to be transferred to the dialed number, and freeing up the trunk 3 to handle another incoming call. Control then passes to step 1917 where the `external message center count` 721 in the subscriber master record 700 is incremented. Control then passes to steps 1909 and 1910 where a page is generated as described above, before returning control to the connector labelled "CPF IDLE" at reference 1911.
A flowchart of the CPF--Voice Screen function is illustrated in FIGS. 20a, 20a-1, 20b, and 20c. The purpose of this function is to process calls for a subscriber who has selected the `voice screen` call handling mode. The CPF--Voice Screen function is entered at step 2000 and control passes to step 2001 where the caller is prompted by call processor 435: "Please state your name and business at the tone. After the tone please stay on the line while we attempt to locate your party and connect your call . . . BEEP." Control then passes to step 2090 where a determination is made as to whether the caller has entered the `VIP screen code` 714, and if so control passes to the "CPF--Announced Forwarding" function as shown at step 2091. In this way, a caller who knows the `VIP screen code` is able to be forwarded directly to the subscriber without being voice-screened. If, however, at step 2090 it is determined that the caller has not entered the `VIP screen code` 714 then control passes to step 2002 where the caller's message is recorded by call processor 435 and stored temporarily on disk 505. At step 2003, the call processor 435 determines that the caller has completed stating his name and business, by detecting the sound of the voice followed by approximately 3 seconds of silence, at which point the call processor 435 prompts the caller: "Thank you, please standby." A flash is generated at step 2004, causing the caller to be placed on hold by the switch 4, and at step 2005 a pause is initiated to allow time for the switch 4 to provide a dial tone, at which point the transfer number 707 is dialed by the DTMF generator of call processor 435. At step 2006, an `answer timer` is started. At step 2007 a determination is made by call processor 435 as to whether the call has been answered. If the call has not been answered, then at step 2008 a decision is made as to whether a time-out or non-answer signal such as a busy, reorder, or operator intercept has been detected by call processor 435. If so, then control proceeds through a connector labelled "CPF VSCRN FLASH" at reference 2009, to step 2010. Otherwise control returns to step 2207. At step 2010, a flash is generated, causing switch 4 to temporarily conference the caller through to the non-answer signal, and at step 2011 a 2 second pause is invoked. Then at step 2012 another flash is generated causing switch 4 to drop the conference and restore a simple 2-way connection between the caller and the trunk 3. Control then passes to a connector labelled "CPF SORRY" at reference 2013, resulting in the caller being connected to the subscriber's message center as described earlier in FIG. 13. Returning the discussion now to step 2007, if a determination is made that the call is answered, then control passes to step 2014 where the `voice screen PIN code hold-off flag` of options 705 of the master record 700 is checked. If this flag has been set, it means that the subscriber wishes to require that a PIN code be entered by the answering party before the called party's message is played. This is very useful if the subscriber is having his calls voice-screen forwarded to his office, for example, where the receptionist may answer the call. In this case the receptionist would connect the call to the subscriber and the subscriber would enter his PIN code to hear the calling party's message before determining whether he wishes to be connected to the calling party. If this flag is set, then control passes to step 2015, where call processor 435 prompts the answering party: "We are trying to reach . . . ". Then at step 2016, the subscriber's prerecorded `drop-in` name is retrieved from disk 505 and played back to the answering party. At step 2017, the answering party is informed: "Please locate the party or enter your PIN code." Then at step 2018, a 5 second delay is introduced, and at step 2019, a determination is made as to whether the answering party has entered the PIN code 702. If the PIN code is entered, then control passes to step 2021. Otherwise, control passes to step 2020, where a determination is made as to whether the sequence of steps 2015 through 2020 has been repeated ten times. If not, then control returns to step 2015, and the sequence is repeated again. However, if this is the tenth repeat, then control passes to the connector labelled "CPF VSCRN FLASH" at reference 2009, and the calling party is sent to the subscriber's message center as described earlier. If, at step 2014, it is determined that the `voice screen PIN code hold-off flag` is not set, or if it is set and the PIN code has been entered as determined at step 2019, then control passes to step 2021, where the answering party is informed by call processor 435: "We have a call holding for . . . ", and then to step 2022 where the subscriber's `drop-in` name is retrieved from disk and played. Then at step 2023, which is identified by the connector labelled "CPF VSCRN LISTEN" at reference 2024, the caller's message which was originally recorded at step 2002 is retrieved from disk 505 and played by call processor 435 to the subscriber. Then at step 2025, which is identified by the connector labelled "CPF VSCRN MENU" at reference 2026, the subscriber is prompted: "Please touch 1 to connect the call, 2 to send the caller to your message center, 3 to politely send the caller away, 4 to listen to the caller's message again. 5 to place the caller on hold for 1 minute, 6 to transfer the call elsewhere, or 7 to ask the caller not to call again." Control then passes through a connector labelled "CPF VSCRN LOOP" at reference 2027. At reference 2028, the connector labelled "CPF VSCRN LOOP" passes control to step 2029 where a 10 second timer is started. Then at step 2030, a determination is made as to whether a digit has been entered by the subscriber, and if so control passes to step 2033. Otherwise, control passes to step 2031 where the 10 second timer is checked, and if it has not expired control returns to step 2030. If the timer has expired, then control is passes to the connector labelled "CPF VSCRN FLASH" at reference 2032, and the caller is connected to the message center as described earlier. If a digit has been entered by the subscriber, then at step 2033, the digit is checked and if it is not `1`, control is passes to step 2043. If the digit is `1`, then control passes to step 2034, where a flash is generated causing the calling party and the subscriber to be conferenced by switch 4. Then at step 2035 a determination is made as to whether dial tone is present on the line. If so this would indicate that the conference failed, most likely because the calling party had hung up. If this is the case, then control passes to step 2039. Otherwise, if dial tone is not detected, then at step 2036, both the calling party and the subscriber hear call processor 435 play the prompt: "Go ahead please.", and at step 2037, the trunk 3 is placed on hook causing the switch 4 to transfer the call allowing the calling party and the subscriber to continue their conversation, while at the same time freeing up trunk 3 to handle another incoming call by passing control back to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2038. If the caller had hung up as determined by the detection of dial tone at step 2035, then at step 2039 another flash is generated to cause switch 4 to take the subscriber off of hold. Then at step 2040, the subscriber is informed: "I'm sorry, your party has hung up", and at step 2041 trunk 3 is placed on hook and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2042. If, as described earlier, at step 2033 it is determined that the digit is not `1`, then control is passes to step 2043 where it is determined whether the digit is a `2`, and if so control is passes to the connector labelled "CPF VSCRN FLASH" at reference 2044 causing the calling party to be connected to the message center as was described earlier. If the digit is not `2`, then control passes to step 2045, where it is determined if the digit is a `3`, and if not control passes to step 2052. If the digit is a `3`, then control passes to step 2046, where a flash is generated causing switch 4 to temporarily conference the calling party and the subscriber. Then. after a 2 second pause at step 2047, another flash is generated at step 2048 causing switch 4 to terminate the conference by dropping the subscriber, leaving just the calling party connected to trunk 3. Then at step 2049, the calling party is informed by call processor 435: "I'm sorry, your party is unable to take your call at this time. Thank you for calling. Good-bye." Then at step 2050, the trunk 3 is placed on hook thereby disconnecting the calling party and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2051. If, as described earlier, at step 2045 it is determined that the digit is not `3`, then control is passes to step 2052 where it is determined whether the digit is a `4`, and if so control is passes to the connector labelled "CPF VSCRN LISTEN" at reference 2053, allowing the subscriber to again hear the calling party's message as described earlier. If at step 2052 it is determined that the digit is not a `4`, then control passes to step 2054 where the digit is checked to determine if it is a `5`, and if it is not control passes to a connector labelled "CPF VSCRN DIGIT" at reference 2060. If the digit is a '5, then control passes to step 2055 where a one minute timer in started. Then at step 2056 a determination is made whether any further digits have been entered by the subscriber, and if not control passes to step 2058 where the one minute timer is checked. If the timer is found to have expired, then control passes to a connector labelled "CPF VSCRN MENU" at reference 2059, causing the menu of step 2025 to be replayed to the subscriber. If the timer is found to have not expired, then control returns to step 2056 where a determination is again made as to whether any digits have been entered by the subscriber, and if so control passes to a connector labelled "CPF VSCRN LOOP" at reference 2057, thereby allowing the digit to be processed. The connector labelled "CPF VSCRN DIGIT6" at reference 2061 causes control to be passed to step 2062 where a determination is made as to whether the digit pressed by the subscriber is a 6, and if not control passes to step 2075. If the digit is a `6`, then control passes to step 2063 where the subscriber is prompted by call processor 435: "Please enter the telephone number you wish to have this call transferred to." Then at step 2064, the control idles, waiting for a telephone number to be entered by the subscriber. If a phone number is entered, then control passes to step 2065, where the subscriber is prompted: "Number accepted. Please hang up now." Then at step 2066 a flash is generated causing switch 4 to temporarily conference the calling party and the subscriber. Then, after a 2 second pause at step 2067, another flash is generated at step 2068 causing switch 4 to terminate the conference by dropping the subscriber, leaving just the calling party connected to trunk 3. Then at step 2069 the calling party is prompted by call processor 435: "Please standby." Then at step 2070 a flash is generated causing switch 4 to place the calling party on hold and providing a dial tone to the trunk 3. Then, after a pause for dial tone at step 2071, the phone number detected in step 2064 is dialed at step 2072, and at step 2073 trunk 3 is placed on hook causing switch 4 to transfer the calling party to the phone number dialed, and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2074. If, as described earlier, at step 2062 it is determined that the digit entered by the subscriber is not a `6`, then control passes to step 2075. At step 2075, a determination is made as to whether the digit is a `7`, and if not then control passes to a connector labelled "CPF VSCRN LOOP" at reference 2076 thereby allowing the subscriber to enter another digit. If the digit entered is a `7`, as determined at step 2075, then control passes to step 2077 where a flash is generated causing switch 4 to temporarily conference the calling party and the subscriber. Then, after a 2 second pause at step 2078, another flash is generated at step 2079 causing switch 4 to terminate the conference by dropping the subscriber, leaving just the calling party connected to trunk 3. Then at step 2080 the calling party is prompted by call processor 435: "Your party is not interested in your call. Please remove this party from your list and do not call again. Good-bye." Then at step 2081 trunk 3 is placed on hook causing switch 4 to disconnect the calling party, and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2082.
A flowchart of the CPF--Meet Me Caller function is illustrated in FIGS. 21a and 21b. The purpose of this function is to process calls for a subscriber who has chosen to have his calls handled by the meet-me function. In the preferred embodiment these calls are handled by conferencing the caller on a trunk 3 of the CPF 100 with a line 120 on the Meet-Me Facility (MMF) 115. Then when the subscriber calls in to be connected, he is also conference from a trunk 3 of the CPF 100 with a line 120 on the MMF 115. The CPF may then hang up on both the caller:s trunk 3 and then subscriber's trunk 3, thereby transferring the caller and subscriber to the MMF lines 120. The lines 120 are provisioned with the CENTREX features of `call transfer` and `barge-in`, so that the caller and subscriber may then be connected as follows: The line 120 which is connected to the caller dials the CENTREX barge-in command (*77) followed by the CENTREX `intercom code` for the line 120 which is connected to the subscriber. The caller and the subscriber are thus connected, and the line 120 which connects to the subscriber may then go on hook, transferring the subscriber to the caller's line 120. The conversation may then take place and only one line of line 120 is used. To fully understand the explanation of the CPF--Meet Me Caller function which follows, it is necessary to also review the explanations which are associated with FIG. 30 (CPF--Command Meet Me), FIG. 33 (MMF block diagram), and FIG. 34 (Meet Me Facility Main Task). Referring now to FIGS. 21a and 21b, the CPF--Meet Me Caller function is entered at step 2100 and control passes to step 2101 where the calling party is informed by call processor 435: "We are paging your party to a phone. Please stay on the line." Then at step 2102 a flash is generated causing switch 4 to place the calling party on hold and generate a dial tone on trunk 3. Then at step 2103 the call processor 435 dials the phone number which is associated with one of the lines 120 which are connected to the Meet-Me Facility (MMF) 115, and at step 2104 a 15 second timer is initiated. Then at step 2105, a determination is made as to whether DTMF `*` tone has been detected by call processor 435, indicating that the MMF 115 has answered. If the `*` tone is not detected, then control passes to step 2106 where the 15 second timer is checked, and if found to have not expired then control returns to step 2105. If the 15 second timer is found to have expired, then control passes to step 2107, where a flash is generated causing switch 4 to temporarily conference the calling party to the number dialed above. Then after a 2 second pause at step 2108, another flash is generated at step 2019, causing switch 4 to drop the dialed number from the conference, leaving just the calling party connected to trunk 3. Then at step 2110, a check is made to determine if dial tone is present on trunk 3. If dial tone is found to be present, indicating that the sequence of steps 2197 through 2109 had failed to restore the calling party possibly because the conference thought to be created at step 2107 was not allowed by switch 4, then another flash is generated at step 2111, which is identified by a connector labelled "CPF MM FLASH" at reference 2134. This flash causes switch 4 to reconnect the calling party to trunk 3, and then control passes via a connector labelled "CPF MSSG" at reference 2112 to step 2113. If dial tone is not detected at step 2110, then control passes directly to step 2113. At step 2113, the current time and date is stored in the `last meet-me message left` field 720 of the subscriber master record 700, and then control passes to the connector labelled "CPF SORRY" at reference 2114, causing the caller to be connected to the message center as was described earlier. If at step 2105, the `*` tone is detected, indicating that the MMF 115 has answered, then control passes to step 2115 where call processor 435 dials the digit `00` signifying that this is a caller, not a subscriber. Then at step 2116, the call processor 435 dials the subscriber's DID number 701, to identify to the MMF who the calling party is waiting for. Then at step 2117, a flask is generated, causing switch 4 to conference the calling party through to this line 120 of the MMF 115, and at step 2118 a 2 second timer is initiated. Then at step 2119, a determination is made as to whether another `*` tone is detected by call processor 435, indicating the conference was successful. If the `*` tone is not detected, this implies that the conference was not successful, most likely because the calling party has hung up. In this case the 2 second timer is checked at step 2120, and if it is found not to have expired control returns to step 2119. If the 2 second timer has expired, then control passes via a connector labelled "CPF MM ABANDON" at reference 2121 to step 2122 where the current time and date are stored in the `last meet-me abandon` field 719 of the subscriber master record. Then control passes to step 2123 where the trunk 3 is placed on hook and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2124. If at step 2119 the `*` tone is detected, then control passes to step 2125 where a repeat count is set to a value of 3. Then at step 2126, the calling party is informed by call processor 435: "We have sent a page to alert your party of the call. Your party is currently proceeding to a phone and we will connect you momentarily. If you are unable to wait, you may touch 9 at any time to leave a detailed message which we will relay to your party as soon as they pick up the line." Then at step 2127, the call processor 435 plays a `music on-hold` selection of duration 40 seconds. Then at step 2128 a determination is made as to whether the subscriber has called in, by checking the CPF--Call Handler Tasks controlling the other trunks 3 connected to the CPF 100. If the subscriber is found, and if he has entered his PIN code 702 and touched 4 indicating he wishes to be connected to the caller, then step 2128 will return a positive indication causing control to pass to the connector labelled "CPF MM SUBCALL" at reference 2129. If a negative indication is returned at step 2128, then control passes to step 2130 where a determination is made as to whether the caller has entered `9`. If the caller does enter `9`, then control passes to step 2111, causing the caller to be connected to the message center as describer earlier. If the caller has not entered `9`, then control passes to step 2131, where a determination is made as to whether the 40 second music-on-hold selection is complete. If it is not complete, then control returns to step 2128. If the selection is complete, then control passes to step 2132 where the repeat count is decremented. Then at step 2133 a determination is made as to whether the value of the repeat count is now zero. If the value is zero, then control passes to step 2111, causing the caller to be connected to the message center as describer earlier. If the value of the repeat count is not yet zero, then control returns to step 2127, where the sequence of steps 2127 through 2133 is repeated once more. The connector labelled "CPF MM SUBCALL" at reference 2135 causes control to be passed to step 2136 where the DTMF fourth column tone digit `d` is dialed by call processor 435 to inform the MMF 115 that the subscriber has arrived. Then at step 2137, the call processor 435 prompts the calling party: "Your party has picked up the line. One moment and we will connect you." Then at step 2138, a 20 second timer is initiated, and at step 2139 the call processor 435 begins to play audible ringing, with a cadence of 2 seconds on, 4 seconds off, to the caller. Then at step 2140, the 20 second timer is checked, and if it is found to have expired, indicating that the subscriber did not connect to the MMF 115, then control passes to the connector labelled "CPF MM FLASH" at reference 2141, causing the caller to be connected to the message center as was described earlier. If the 20 second timer has not expired, then control passes to step 2142 where a determination is made as to whether the subscriber has connected to the MMF 115, as determined by checking with the CPF--Call Handler Task that was found to be controlling the trunk 3 connected to the subscriber. If the subscriber has not connected to the MMF 115, then control returns to step 2140. If the subscriber has connected to the MMF 115, then the trunk 3 is placed on hook causing switch 4 to transfer the calling party to the line 120 of the MMF 115, and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2144.
A flowchart of the CPF--Send Page Subroutine is illustrated in FIG. 22. The purpose of this subroutine is to send page messages via the high speed data network 150 from the CPF 100 to either the PDF 105, or the CAF 125. These messages contain the pager number and any digits which are to be transmitted to the display of the pager. The CPF--Send Page Subroutine is entered at step 2200 and control passes to step 2201 where the pager number 710 for this subscriber is retrieved from the subscriber master record 700. Then at step 2202, a message is constructed consisting of the pager number 710, and the display digits which were identified as this subroutine was called. Then at step 2203 a determination is made as to whether the pager number 710 represents a communicator. In the preferred embodiment, each communicator 11 is identified by a pager number 710 which starts with the digits `000`. If the pager number 710 is found to be that of a communicator 11, then control passes to step 2204, and the data network interface 510 is instructed to send the message via network 150 to the Communicator Access Facility (CAF) 125, and then control is returned from this subroutine to the calling program, as represented at step 2206. If the pager number 710 is not found to be that of a communicator 11, then control passes to step 2205, where the data network interface 510 is instructed to send the message via network 150 to the Pager Dialing Facility (PDF) 105, and then control is returned from this subroutine to the calling program, as represented at step 2206.
A flowchart of the CPF--Command Mode function is illustrated in FIGS. 23a and 23b. The CPF--Command Mode function is entered at step 2300 and control passes to step 2301 where the subscriber's pre-recorded `drop-in` name is retrieved from disk 505. Then at step 2302, the call processor 435 prompts the subscriber: "Hello . . . ", and then plays the back the `drop-in` name. Then at step 2303, a determination is made as to whether a meet-me call is currently holding for this subscriber. This is determined by checking the CPF--Call Handler Tasks which control the other trunks 3 connected to CPF 100. If a meet-me call is found to be holding for this subscriber, then at step 2304, the subscriber is prompted: "A call is holding on your meet-me service. Touch 4 to be connected to the caller." Control then passes to step 2317. If a meet-me call is not holding for this subscriber, then control passes to step 2305 where a determination is made as to whether a meet-me caller was recently holding, but hung up without leaving a message. If the time and date stored in the `last meet me abandon` field 719 of the subscriber master record 700 is not more than 20 minutes older than the current date and time, then it is determined that a meet-me caller recently abandoned a call, and control passes to step 2306 where the subscriber is prompted: "A call was recently holding on your meet-me service, however the caller chose not to wait and hung up without leaving a message." Control then passes to step 2307 where the `last meet-me abandon` field 719 of the subscriber master record 700 is cleared. Control then passes to step 2308. Control also passes to step 2308 if, at step 2305, it is determined that a meet-me caller did not recently abandon a call. At step 2308, a determination is made as to whether a meet-me caller is currently leaving a message for the subscriber. This is determined by checking the CPF--Call Handler Tasks which control the other trunks 3 connected to CPF 100. If it is determined that a meet-me caller is currently leaving a message for this subscriber, then control passes to step 2309, where the subscriber is prompted: "A call was recently holding on your meet-me service, however the caller chose not to wait and is currently leaving you a message. When the message is complete we will connect you to your message center, or you may touch * now to skip this." Control then passes to step 2310 where `music-on-hold` is played to the subscriber by call processor 435. Control then passes to step 2311 where a determination is made as to whether the meet-me caller has finished leaving the message. If the message is complete, then control passes to the CPF--Command Message Center function as shown at reference 2313. If the caller is still leaving the message, then control passes to step 2312 where a determination is made as to whether the subscriber has entered the `*` digit. If the `*` digit is not entered, then control returns to step 2311. If the `*` digit is entered, then control passes to step 2317. If at step 2308, a determination is made that a meet-me caller is not currently leaving a message for this subscriber, then control passes to step 2314, where a determination is made as to whether a meet-me caller recently left a message for this subscriber. If the time and date stored in the `last meet me message left` field 720 of the subscriber master record 700 is not more than 20 minutes older than the current date and time, then it is determined that a meet-me caller recently left a message, and control passes to step 2315 where the subscriber is prompted: "A call was recently holding on your meet-me service, however the caller chose not to wait and instead left you a message." Control then passes to step 2316 where the `last meet-me message left` field 720 of the subscriber master record 700 is cleared. Control then passes to step 2317. Control also passes to step 2317 if, at step 2314, it is determined that a meet-me caller did not recently leave a message. At step 2317, a determination is made as to whether the subscriber has selected an external message center. As described earlier, this determination is made by examining the message center number 709 in the subscriber master record 700. If the message center number 709 contains a phone number, then external has been selected. If the message center number 709 does not contain a phone number, then internal message center has been selected. If, at step 2317, it is determined that the subscriber has selected an external message center, then control passes to step 2318, where the caller is prompted: "We have transferred . . . ". Control then passes to step 2319 where the `external message center transfer count` 721 is retrieved from the subscriber master record 700, and is voiced to the subscriber by call processor 435. Control then passes to step 2320, where the prompt is completed by playing: " . . . since you last checked messages." Control then passes to the connector labelled "CPF MODE DESCR" at reference 2323. If, at step 2317, it is determined that the subscriber had selected the internal message center, then control passes to step 2321 where the number of messages currently stored for this subscriber on disk 505 is determined. At step 2322 then, the call processor 435 prompts the subscriber: "You have X messages.", where X is the number determined above. Control then passes to the connector labelled "CPF MODE DESCR" at reference 2323. The connector labelled "CPF MODE DESCR" at reference 2324, causes control to be passed to step 2325, where a description is played of the current call handling mode. This description includes the current mode memory number 715, the current call handling mode 703, and the current transfer number 707, if appropriate. For example, the subscriber may hear: "Your calls are currently being handled by mode memory 10, urgent-screened forwarding to 555-1111." If the transfer number 707 is the tag for the subscriber's home, office, pager, mobile-phone, or message center, then this would be voiced in words, i.e.: " . . . to your home." After playing a description of the current call handling mode, then control passes to step 2326, where a determination is made as to whether the feature timer is currently active. As was described earlier, this determination is made by checking the feature timer duration 724. If the feature timer is found to be active, then it's status is voiced to the subscriber at step 2327. For example, the subscriber may be prompted: "The feature timer is currently active and will cause mode memory 10 to be invoked at 5:30 today." Control then passes to step 2328. Control also passes to step 2308 if the feature timer was found to be inactive at step 2326. At step 2328, a determination is made as to whether the weekly schedule is active. This determination is made by checking the weekly schedule active flag 728 of the subscriber master record 700. If the weekly schedule is found to be active, then the status of the weekly schedule is voiced to the subscriber at step 2329. For example, the subscriber may be prompted: "The weekly schedule is on, and the next step will cause memory 20 to be invoked at 7:30 PM on Tuesday." Control then passes via connector labelled "CPF MAIN DIRECTORY" at reference 2330 to step 2331. Control also passes via connector 2330 to step 2331 if the weekly schedule is found to be inactive at step 2328. It step 2331 the call processor 435 prompts the subscriber: "Main Directory. Enter 1 to check messages, 2 to change your forwarding number, 3 to select a memory, 9 to make a call, or 0 for help." Control then passes to a loop consisting of steps 2332 through 2339. At each of these steps a determination is made as to whether a particular digit has been entered by the subscriber. If the result is positive on any of these steps, then control is passed to another function. If the digit `1` is found at step 2332, then control passes to the CPF--Command Message Center function, as shown at reference 2340. If the digit `2` is found at step 2333, then control passes to the CPF--Command Forwarding Number function, as shown reference 2341. If the digit `3` is found at step 2334, then control passes to the CPF--Command Memory function, as shown at reference 2342. If the digit `9` is found at step 2335, then control passes to the CPF--Command Outside Call function, as shown at reference 2343. If the digit `0` is found at step 2336, then control passes to the CPF--Command Help function, as shown at reference 2344. If the digit `4` is found at step 2337, then control passes to the CPF--Command Meet Me function, as shown at reference 2345. If the digit `5` is found at step 2338, then control passes to the CPF--Command Branch Route function, as shown at reference 2346. If the digit `8` is found at step 2339, then control passes to the CPF--Command Advanced features function, as shown at reference 2347.
A flowchart of the CPF--Command Message Center function is illustrated in FIG. 24. The CPF--Command Message Center function is entered at step 2400 and control passes to step 2401 where a determination is made as to whether the subscriber has selected an external message center. As described earlier, this determination is made by examining the message center number 709 in the subscriber master record 700. If the message center number 709 contains a phone number, then external has been selected. If the message center number 709 does not contain a phone number, then internal message center has been selected. If, at step 2401, it is determined that the subscriber has selected an external message center, then control passes to step 2402, where the caller is prompted: "Please standby." Control then passes to step 2403 where a flash is generated causing switch 4 to place the subscriber on hold a apply a dial tone to trunk 3. Then, after pausing for dial tone at step 2404, the message center number 709 is dialed by call processor 435 at step 2405. Then at step 2406, the trunk 3 is placed on hook, causing switch 4 to transfer the subscriber to the message center number. Then at step 2407, the `external message center transfer count` 721 of the subscriber master record 700 is cleared. Control is then returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2408. If, at step 2401, it is determined that the subscriber has selected internal message center, then control passes to step 2409, where a determination is made as to whether the subscriber are no messages stored on disk 505. If there are no messages stored for this subscriber, then control passes to step 2410, where the subscriber is informed: "You have no messages." Then at step 2411, the subscriber is prompted: "Enter 8 to return to the main directory." Control then passes to step 2412, where a determination is made as to whether the digit `8` has been entered, and if it has not been entered, then control returns to step 2410. If the digit `8` has been entered, then control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2413, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2409, the determination is made that the subscriber does have messages stored on disk 505, then control passes to step 2414, where one of the stored messages is played back to the subscriber, and the subscriber is given the opportunity to save or delete the message by entering the digits `1` or `2` respectively. Control then passes to step 2415, where a determination is made as to whether the digit `9` has been entered. If the digit `9` is entered, then control passes to the CPF--Command Outside Call function as shown at reference 2416, where the subscriber is given the opportunity to make a call, perhaps returning a call to the person who left the message. If the digit `9` was not entered, then control passes to step 2417, where a determination is made as to whether any more messages are stored on the disk 505. If more messages exist, then control is returned to step 2414. If no more messages exist, then control passes to step 2418, where the subscriber is prompted: "You have no more messages. Enter 8 to return to the main directory." Control then passes to step 2419, where a determination is made as to whether the digit `8` has been entered, and if it has not been entered, then control returns to step 2418. If the digit `8` has been entered, then control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2413, allowing the subscriber to make additional selections from the main directory of the command mode.
A flowchart of the CPF--Command Forwarding Number function is illustrated in FIG. 25. The CPF--Command Forwarding Number function is entered at step 2500 and control passes to step 2501 where a determination is made as to whether the current call handling mode 703 for this subscriber is `message center` or branch routing`. Since it is not logical to change a forwarding number in a mode that does not require a forwarding number, if it is determined that either of these modes are active, then control will pass to step 2502, where the subscriber will be prompted: "Invalid command." Control then passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2503, allowing the subscriber to make additional selections from the main directory of the command mode. If, at step 2501, it is determined that the current call handling mode 703 is not `message center` or `branch routing`, then control passes to step 2504, where a determination is made as to whether the transfer number 707 is set equal to the `meet-me tag`. If so, then control passes to step 2505, where the subscriber is prompted: "Your calls are currently being forwarded to you via your meet me service." Control then passes to step 2508. If, at step 2504, it is determined that the forwarding number is not equal to the `meet-me tag` then control passes to step 2506, where the subscriber is prompted: "Your calls are currently being forwarded to . . . " Control then passes to step 2507, where the transfer number 707 is retrieved from the subscriber master record 700, and voiced to the subscriber. Control then passes to step 2508, where the subscriber is prompted: "Please enter your new forwarding number, or enter * to skip this, or enter 6 to use your meet-me service." Control then passes to step 2509, where a determination is made as to whether the subscriber has entered a valid phone number, or a tag for home, office, or mobile phone. If so, then control passes to step 2510, where the phone number is stored as the new transfer number 707 in the subscriber master record 700, and the subscriber is prompted: "Accepted, your calls are currently being forwarded to . . . ", and the transfer number 707 is voiced. Control then passes to the CPF--Command Feature Timer function as shown at reference 2511. If it is determined at step 2509 that the subscriber has not entered a phone number, then control passes to step 2512, where a determination is made as to whether the subscriber has entered the digit `6`, and if so control passes to step 2513 where the `meet-me tag` is stored as the transfer number 707 in the subscriber master record 700, and the subscriber is prompted: "Accepted, your calls are currently being forwarded to you via your meet-me service." Control then passes to the CPF--Command Feature Timer function as shown at reference 2511. If it is determined at step 2512 that the digit `6` has not been entered, then control passes to step 2514, where a determination is made as to whether the digit `*` has been entered, and if not control returns to step 2509. If the digit `*` has been entered, then the transfer number 707 remains unchanged, and control passes to the CPF--Command Feature Timer function as shown at reference 2511.
A flowchart of the CPF--Command Feature Timer function is illustrated in FIG. 26. The CPF--Command Feature Timer function is entered at step 2600 and control passes to step 2601 where the subscriber is prompted: "Please enter the length of time you wold like your current feature to be in effect, or enter * to skip the feature timer." Control then passes to step 2602, where a determination is made as to whether the digit `*` has been entered by the subscriber. If the digit `*` has been entered, then control passes to step 2603, where the subscriber is prompted: "Accepted, your feature will be in effect until further notice." Control then passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2613, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2602, it is determined that the digit `*` has not been entered, then control passes to step 2604 where a determination is made as to whether a valid duration has been entered. This duration must be in the form of hours first followed by minutes. For example, to enter 1 hour and 20 minutes, the subscriber must enter `1 2 0`. If a valid duration is not found to be entered at step 2604 then control returns to step 2602. If a valid duration is entered, then control passes to step 2605, where the duration is stored as the `feature timer duration` 724 of the subscriber master record 700, and the subscriber is prompted: "Accepted, . . . " and the duration time is voiced. Control then passes to step 2606 where the subscriber is prompted: "Please enter the memory number you wish to invoke upon termination of the feature timer, or enter * to use the previous mode, or touch 9 to use the schedule." Control then passes to step 2607, where a determination is made as to whether the subscriber has entered the digit `*`, and if so then at step 2608 the previous mode memory is saved in temporary mode memory 0, mode memory 0 is stored as the feature timer termination mode 725 of the subscriber master record, and the subscriber is prompted: "Accepted, your feature will be in effect until (time) at which time the previous mode will be invoked.", where the value of (time) corresponds to the current time plus the feature timer duration 724. Control then passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2613, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2607 it is determined that the digit `*` has not been entered, then control passes to step 2609, where a determination is made as to whether the digit `9` is entered, and if so control passes to step 2610 where the weekly schedule is saved in temporary mode memory 0, mode memory 0 is stored as the feature timer termination mode 725 of the subscriber master record, and the subscriber is prompted: "Accepted, your feature will be in effect until (time) at which time the weekly schedule will be invoked.", where the value of (time) corresponds to the current time plus the feature timer duration 724. Control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2613, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2609 it is determined that the digit `9` has not been entered, then control passes to step 2611, where a determination is made as to whether a valid mode memory 10 through 99 is entered, and if so control passes to step 2612 where the mode memory is stored as the feature timer termination mode 725 of the subscriber master record, and the subscriber is prompted: "Accepted, your feature will be in effect until (time) at which time mode memory XX will be invoked.", where the value of (time) corresponds to the current time plus the feature timer duration 724. Control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2613, allowing the subscriber to make additional selections from the main directory of the command mode.
A flowchart of the CPF--Command Memory function is illustrated in FIG. 27. The CPF--Command Memory function is entered at step 2700 and control passes to step 2701 where the subscriber is prompted: "Your calls are currently being handled via mode memory XX.", where XX is the current mode memory number 715 of the subscriber master record. Control then passes to step 2702, where a description of the mode is voiced to the subscriber. This description includes the current call handling mode 703, and the current transfer number 707, if appropriate. For example, the subscriber may hear: "Your calls are currently being urgent-screened forwarded to 555-1111." If the transfer number 707 is the tag for the subscriber's home, office, pager, mobile-phone, or message center, then this would be voiced in words, i.e.: " . . . to your home." Control then passes to step 2703 where the subscriber is prompted: "Please enter a new mode memory number or enter * to skip this." Control then passes to step 2704 where a determination is made as to whether the digit `*` has been entered. If the digit `*` is entered, then control passes to the CPF--Command Feature Timer function as shown at reference 2722. If at step 2704, it is determined that the `*` digit has not been entered, then control passes to step 2705, where a determination is made as to whether a valid 2 digit mode memory number has been entered, and if such a mode memory number has not been entered, then control returns to step 2703. If a valid mode memory number is entered, then control passes to step 2706, where the mode memory number is stored as the current mode memory number 715 of the subscriber master record 700, the corresponding mode memory 800 is copied to the subscriber master record, the subscriber is prompted: "Accepted, you have selected mode memory XX, which causes your calls to be . . . ", and then control passes to step 2707. At step 2707, the prompt is completed by playing a brief description of the selected mode memory. The description includes the call handling mode 703, and the transfer number 707 if appropriate. For example, at step 2707 the remainder of the prompt may be: " . . . handled by your message center." At step 2708 a determination is made as to whether the selected mode memory requires an `externally entered number`. This is determined by checking the transfer number field 707 of the selected mode memory, to determine if it contains an `externally entered number` tag. If this is the case, then the subscriber must enter a transfer number after selecting this memory. If the externally entered number is not required, then control passes to the CPF--Command Feature Timer function as shown at reference 2722. If it is determined at step 2708 that an externally entered number is required, then control passes to step 2710, where the subscriber is prompted: "Please enter your new forwarding number or enter * to skip this and use . . . ". Control then passes to step 2711 where the previous transfer number is voiced to the subscriber. Control then proceeds to step 2712 where the subscriber is further prompted with: " . . . or enter 6 to use your meet-me service." Control then passes to step 2713 where a determination is made as to whether the digit `*` has been entered. If the digit `*` has been entered then control passes to step 2716. Otherwise, control passes to step 2714 where a determination is made as to whether a phone number or tag has been entered by the subscriber. If not, then control returns to step 2710. If a phone number or tag has been entered, then control passes to step 2715 where the phone number is stored as the transfer number 707 of the subscriber master record 700, the subscriber is prompted: "Accepted . . . ", and the phone number or tag is voiced. Control then passes to step 2716, where a determination is made as to whether the memory has an extension number in the extension number field 708 of the subscriber master record 700. If an extension number does not exist in this field, then control passes to the CPF--Command Feature Timer function as shown at reference 2722. If at step 2716 it is determined that an extension number does exist, then control passes to step 2717 where the subscriber is given an opportunity to modify the extension number. At step 2717 the subscriber is prompted: "Please enter your new extension number or enter * to skip this and use . . . ". Control then passes to step 2718 where the phrase is completed by voicing the current extension number 708. Control then passes to step 2719 where a determination is made as to whether a new extension number has been entered, and if so, then control passes to step 2720 where the extension number is stored in the extension number field 708, the subscriber is prompted: "Accepted, . . . ", the new extension number is voiced, and control passes to the CPF--Command Feature Timer function as shown at reference 2722. If at step 2719 it is determined that an extension number has not been entered then control passes to step 2721, where a determination made as to whether the digit "*" is entered, and if the "*" digit is not entered then control returns to step 2717. If at step 2721 it is determined that the "*" digit is entered then control passes to the CPF--Command Feature Timer function as shown at reference 2722.
A flowchart of the CPF--Command Outside Call function is illustrated in FIG. 28. The CPF--Command Outside Call function is entered at step 2800 and control passes to step 2801 where the call processor 435 plays a `stutter dial tone` to the subscriber. Control then passes to step 2802 where a determination is made as to whether the subscriber has entered the `#` digit. If the `#` digit has been entered, then control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2803, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2802 it is determined that the subscriber has not entered the `#` digit, then control passes to step 2804 where a determination is made as to whether the subscriber has entered a phone number that he wishes to be connected to. If a phone number has not been entered, then control returns to step 2802. If at step 2804 it is determined that a phone number has been entered, then control passes to step 2808, where a flash is generated, causing switch 4 to place the subscriber on hold, and applying a dial tone to the trunk 3. Then, after a pause for dial tone at step 2806, the call processor 435 dials the phone number at step 2807, which had been entered by the subscriber. Control then passes to step 2808, where the `multiple outside calls allowed` flag 729 of the subscriber master record 700 is checked. If this flag is not active, then control passes to step 2809 where the trunk 3 is placed on hook, causing switch 4 to transfer the subscriber to the dialed number, and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2810. If at step 2808 it is determined that the `multiple outside calls allowed` flag 729 is set, then control passes to step 2811, where a flash is generated which causes the subscriber to be conferenced to the dialed number while maintaining trunk 3 in the connection. In this way the subscriber may make additional calls, or later return to the main directory without hanging up and calling back. After the flash is generated at step 2811, control passes to step 2812 where a loop is entered waiting for the subscriber to enter the digit sequence `##`. When trying to detect DTMF digits while conversation may be present, as is the case in this situation, requiring the two digits in sequence reduces the likelihood of falsing on voice. If the subscriber enters `##`, then control passes to step 2813 where a flash is generated causing switch 4 to disconnect the third party from the conference, leaving only the subscriber connected to trunk 3. Control then returns to step 2801, where the subscriber may make another call, or enter `#` to return to the main directory.
A flowchart of the CPF--Command Help function is illustrated in FIG. 29. The purpose of this function is to provide help to the subscriber who is using the Command Mode features of the Telephone Control System. This is accomplished by allowing the subscriber to enter the digit `0` for help from any of the command mode functions. Once the digit `0` is entered, the subscriber is provided with an explanation of the function which was being accessed at that moment. The subscriber may also touch another digit `0` to reach a live client services representative. The CPF--Command Help function is entered at step 2900 and control passes to step 2901 where the step number of the function from which the CPF--Command Help was requested is saved for later use. Then at step 2902, the subscriber is prompted: "You have selected the help function. You may enter 0 to be connected to a client services operator, 8 to return to the main directory, or # to return to the point where you were when you entered the help function." Control then passes to step 2903, where a context sensitive help prompt is played, based on the step number saved in by step 2901. For example, if the saved step number indicated that the help function was accessed while in the CPF--Command Forwarding Number function, then the call processor 435 would play the prestored help prompt associated with that function: "When you selected the help function you were in the process of changing your forwarding number." Control then passes to step 2904 where a determination is made as to whether the digit `0` has been entered, and if so, control then passes to step 2905 where a flash is generated, causing switch 4 to place the subscriber on hold, and applying a dial tone to the trunk 3. Then, after a pause for dial tone at step 2906, the call processor 435 dials the phone number at block 2907, which is associated with a client services representative. Control then passes to step 2908 where the trunk 3 is placed on hook, causing switch 4 to transfer the subscriber to the dialed number, and control is returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 2909. If at step 2904 it is determined that the digit `0` is not entered, then control passes to step 2910 where a determination is made as to whether the digit `8` has been entered, and if so, control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 2911, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 2910 it is determined that the digit `8` is not entered, then control passes to step 2912 where a determination is made as to whether the digit `#` is entered, and if not control returns to step 2902. If the digit `#` is entered, then the step number that was saved at step 2901 is retrieved and the control returns to that step.
A flowchart of the CPF--Command Meet Me function is illustrated in FIG. 30. The purpose of this function is to process the call for a subscriber who has called in, entered his PIN code 702, and wishes to be connected to a meet-me caller who is holding for him. The CPF--Command Meet Me function is entered at step 3000 and control passes to step 3001 where a flash is generated, causing switch 4 to place the subscriber on hold and apply a dial tone to the trunk 3. Then, after pausing for dial tone at step 3002, the call processor 435 dials the phone number of the lines 120 which are connected to the Meet Me Facility (MMF) 115 at step 3003. Control then passes to step 3004 where a 15 second timer is started, and then to step 3005 where the 15 second timer is checked. If the 15 second timer has not expired, then control passes to step 3006 where a determination is made as to whether a `*` digit is detected, indicating that the MMF 115 has answered the call. If the `*` digit is not detected then control returns to step 3005. If at step 3006, the `*` digit is detected, then control passes to step 3007 where the call processor 435 dials `01` indicating this call is from a subscriber, and then dials the subscriber's DID number 701, thereby fully identifying the call to the MMF 115. Control then passes to step 3008 where a flash is generated causing switch 4 to take the subscriber off of hold and create a conference between the subscriber, trunk 3, and the line 120 of the MMF 115. Control then passes to step 3009 where a 4 second pause is initiated to allow the MMF 115 time to connect the caller into the call. Control then passes to step 3010 where the subscriber and caller are prompted by call processor 435: "Go ahead please." Control then passes to step 3011 where the trunk 3 is placed on hook, causing the switch 4 to transfer the subscriber to the line 120 of the MMF 115. Control is then returned to the CPF--Call Handler Task via the connector labelled "CPF IDLE" at reference 3012. If at step 3005 it is determined that the 15 second timer had expired, indicating that the MMF 115 had not answered the call, then control passes to step 3013 where a flash is generated causing switch 4 to create a temporary conference between the subscriber and the dialed number, and then after a 2 second pause at step 3014 another flash is generated at step 3015 causing switch 4 to drop the dialed number from the conference and leave just the subscriber connected to the trunk 3. Control then passes to step 3016 where the subscriber is prompted: "I'm sorry, we are unable to connect your call at this time." Control then passes to the connector labelled "CPF MAIN DIRECTORY" at reference 3017, allowing the subscriber to make additional selections from the main directory of the command mode.
A flowchart of the CPF--Command Branch Route function is illustrated in FIGS. 31 and 31a. The CPF--Command Branch Route function is entered at step 3100 and control passes to step 3101 where a determination is made as to whether the current call handling mode 703 is `branch-routing`, and if it is not control is passes to step 3102 where the subscriber is prompted: "Invalid command.", and control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 3103, allowing the subscriber to make additional selections from the main directory of the command mode. If at step 3101 it is determined that the call handling mode 703 is `branch routing` then control passes to step 3104 where the subscriber is prompted: "Enter 1 to record a new branch routing greeting, 2 to change branch routing numbers, 3 to change the branch routing default number, or `#` to return to the main directory." Control then passes to step 3105 where a determination is made as to whether the digit `1` is entered, and if so, control passes to step 3106 where the subscriber is prompted: "Your branch routing greeting is . . . ". Then at step 3107, the branch routing greeting for this subscriber is retrieved from disk 505 and played back to the subscriber. Control then passes to step 3108 where the subscriber is prompted: "Please record your new branch routing greeting at the tone, or enter * to skip this and use the existing branch routing greeting . . . BEEP." Then at step 3109, the new greeting is recorded and control passes to step 3110 where a determination is made as to whether the greeting is done, and if it is control passes to step 3111 where the new branch routing greeting is saved to disk 505 and then control returns to step 3104. If at step 3110 it is determined that the greeting is not done, then control passes to step 3112 where a determination is made as to whether the digit `*` is entered, and if not control returns to step 3109. If at step 3112 it is determined that the digit `*` is entered, then control passes to step 3113 where the old branch routing greeting on disk 505 is left unchanged, and control then passes to step 3104. If at step 3105 it is determined that the digit `1` is not pressed, then control passes to step 3114 where a determination is made as to whether the digit `2` is entered, and if it is entered then control passes to step 3115 where the subscriber is prompted: "Please enter the branch routing directory digit 1 to 9 for the phone number your wish to change, or touch * to skip this." Control then passes to step 3116 where a determination is made as to whether the digit `*` is entered, and if it is entered control returns to step 3104. If at step 3116 it is determined that the digit `*` is not entered, then control passes to step 3117 where a determination is made as to whether one of the digits `1` to `9` are entered, and if one of those digits is entered control then passes to step 3118. Otherwise control returns to step 3116. At step 3118 the subscriber is prompted: "The branch routing transfer number for digit X is . . . ". Control then passes to step 3119 where the branch routing number 722 that corresponds to the digit entered in step 3117 is retrieved from the subscriber master record 700 and voiced to the subscriber. Then at step 3120 the subscriber is prompted: "Please enter the new branch routing transfer number or touch * to skip this without making a change." Control then passes to step 3121 where a determination is made as to whether the digit `*` is entered, and if it is entered control returns to step 3104. If at step 3121 it is determined that the digit `*` is not entered, then control passes to step 3122 where a determination is made as to whether a phone number has been entered, and if a phone number has not been entered, control returns to step 3121. If at step 3122 a phone number is entered, then control passes to step 3123 where the subscriber is prompted: "Accepted." Then at step 3124 the new phone number is voiced to the subscriber. Control then passes to step 3125 where the new phone number is saved as the branch routing number 722 which corresponds to the digit entered in step 3117. Control then returns to step 3104. If at step 3114 it is determined that the digit `2` is not entered, then control passes to step 3126 where a determination is made as to whether the digit `3` is entered, and if it is entered, then control passes to step 3127 where the subscriber is prompted: "The branch routing default transfer number is . . . " Control then passes to step 3128 where the branch routing default number 723 is retrieved from the subscriber master record 700 and voiced to the subscriber. Then at step 3129 the subscriber is prompted: "Please enter the new branch routing default transfer number, or touch * to skip this without making a change." Control then passes to step 3130 where a determination is made as to whether the digit `*` is entered, and if the digit `*` is entered control returns to step 3104. If at step 3130 it is determined that the digit `*` is not entered, then control passes to step 3131 where a determination is made as to whether a phone number has been entered, and if a phone number has not been entered control returns to step 3130. If it is determined at step 3131 that a phone number has been entered, then control passes to step 3132 where the subscriber is prompted: "Accepted." Control then passes to step 3133 where the new phone number is voiced to the subscriber. Control then passes to step 3134 where the new phone number is saved as the branch routing default number 723 in the subscriber master record. Control then returns to step 3104. If at step 3126 it is determined that the digit `3` is not entered, then control passes to step 3135 where a determination is made as to whether the digit `#` is entered, and if it is not entered control then returns to step 3104. If at step 3135 it is determined that the digit `#` is entered then control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 3136, allowing the subscriber to make additional selections from the main directory of the command mode.
A flowchart of the CPF--Command Advanced Features function is illustrated in FIG. 32. The purpose of this function is provide the subscriber with the opportunity to modify those features of the Telephone Control System 1 which do not need to be modified on a regular basis. These features include allowing the subscriber to program mode memories, allowing the subscriber to record his `drop-in` name, or his personalized greeting, allowing the subscriber to program his reserved numbers, and allowing the subscriber to activate or deactivate the weekly schedule. The CPF--Command Advanced Features function is entered at step 3200 and control passes to step 3201 where the subscriber is prompted: "Advanced Features Directory. Enter 1 to program mode memories, 2 to record greetings, 3 to program reserved numbers, 4 to activate the weekly schedule, 5 to deactivate the weekly schedule, or # to return to the Main Directory." Control then passes to step 3202 where a determination is made as to whether the digit `1` is entered. If the digit `1` is entered, then control passes to step 3203 where the subscriber is allowed to specify a mode memory number 802 of value `10` to `99`. If the mode memory number 802 specified already exists the call processor voices the status of that memory. The subscriber is then given an opportunity to modify the parameters 803 contained in the mode memory. When the subscriber is finished modifying the contents, the changes are saved in mode memory 800. Control then returns to step 3201. If at step 3202 it is determined that the digit `1` is not entered, then control passes to step 3204 where a determination is made as to whether the digit 2 is entered. If the digit `2` is entered, then control passes to step 3205 where the subscriber is allowed to listen to and re-record the `drop-in` name and the `personalized greeting`. If the subscriber does re-record either of these, then the changed name or greeting is saved on disk 505. Control then returns to step 3201. If at step 3204 it is determined that the digit `2` is not entered, then control passes to step 3206 where a determination is made as to whether the digit `3` is entered. If the digit `3` is entered, then control passes to step 3207 where the subscriber is allowed to modify the `message center number` 709, the `pager number` 710, the `office number` 711, the `home number` 712, or the `mobile phone number` 713. If the subscriber changes any of these numbers then the new number is saved in the corresponding field of the subscriber master record 700. Control then returns to step 3201. If at step 3206 it is determined that the digit `3` is not entered, then control passes to step 3208 where a determination is made as to whether the digit `4` is entered. If the digit `4` is entered, then control passes to step 3209 where the subscriber is allowed to activate the weekly schedule. If the subscriber chooses to activate the weekly schedule, then the `weekly schedule active` flag 728 of the subscriber master record 700 is set. Control then returns to step 3201. If at step 3208 it is determined that the digit `4` is not entered, then control passes to step 3210 where a determination is made as to whether the digit `5` is entered. If the digit `5` is entered, then control passes to step 3211 where the subscriber is allowed to deactivate the weekly schedule. If the subscriber chooses to deactivate the weekly schedule, then the `weekly schedule active` flag 728 of the subscriber master record 700 is cleared. Control then returns to step 3201. If at step 3210 it is determined that the digit `5` is not entered, then control passes to step 3212 where a determination is made as to whether the digit `#` is entered. If the digit `#` is not entered, then control returns to step 3201. If at step 3212 it is determined that the digit `#` is entered then control passes to the connector labelled "CPF MAIN DIRECTORY" at reference 3213, allowing the subscriber to make additional selections from the main directory of the command mode.
A block diagram of the Meet-Me Facility (MMF) 115 is illustrated in FIG. 33. As was discussed earlier, the MMF 115 interfaces to tip-ring lines 120. These lines are provisioned by switch 4 with the CENTREX feature of `call transfer`, which allows a caller to be transferred to another number by flashing, dialing the number, and then going on hook. These lines are also provisioned by switch 4 with the CENTREX feature of `barge-in`, which allows a party on one of the lines 120 to barge into a conversation in progress on another of the lines 120. This is accomplished by flashing, dialing a barge-in code (*77), and then dialing the intercom code associated with the line 120 of the conversation to be barged-in on. As was mentioned earlier, to fully understand the operation of the meet-me feature it is necessary to also review the explanations which are associated with FIGS. 21a and 21b (CPF--Meet Me Caller) FIG. 30 (CPF--Command Meet Me), and FIG. 34 (Meet Me Facility Main Task). Referring now to FIG. 33, the lines 120 are shown connected to call processors 3300, which contain a tip-ring interface and DTMF generators and detectors. The functions of call processor 3300 are well known in the art, and many products, such as the Model D41B manufactured by Dialogic Corporation, exist commercially which can accomplish these functions. The MMF 115 also contains a CPU 3301 which contains among other things a microprocessor, a boot ROM, a RAM, and a disk. The MMF 115 also contains a data network interface module 3302 which connects to the high speed data network 150. The functions of data network interface 150 are well known in the art, and many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. The call processors 3300, the CPU 3301, and the data network interface 3302 are all shown connected to an internal data bus 3303. The CPU 3301 initializes itself at power-up using the boot and then loads a control program into memory which it then executes. The control program allows for the control of simultaneous activities on the lines 120.
A flowchart of the Meet Me Facility Main Task is illustrated in FIG. 34. The Meet Me Facility Main Task is the part of the MMF 115 control program which controls the activities on one of the lines 120. The Meet Me Facility Main Task is entered at step 3400 and control passes to step 3401 where a determination is made as to whether the call processor 3300 has detected a ring signal on the line 120, and if a ring signal is not detected, then control remains at step 3401. If a ring signal is detected, then control passes to step 3402, where the line 120 is taken off hook by call processor 3300, thereby answering the incoming call. At step 3403, a 1 second pause is initiated to allow for the line 120 to settle, and then at step 3404 the call processor 3300 dials the DTMF digit `*` as an answer indication to the CPF 100 which is calling. Then at step 3405 a 5 second timer is started, and control then passes to step 3406 where the 5 second timer is checked. If the 5 second timer has expired, then control passes to step 3407 where the line 120 is placed on-hook by call processor 3300, and then control returns to step 3401. If at step 3406 it is determined that the 5 second timer has not expired, then control passes to step 3408 where a determination is made as to whether the DTMF digit sequence `00` is detected by call processor 3300, indicating the call is a meet-me caller from CPF 100. If the digit sequence `00` is not detected, then control passes to step 3409 where a determination is made as to whether the DTMF digit sequence `01` is detected, indicating the call is a meet-me subscriber from CPF 100. If the digit sequence `01` is not detected, then control returns to step 3406 where the 5 second timer is again checked. If at step 3408 it is determined that the digit sequence `00` is detected, then control passes via a connector labelled "MMF CALLER" at reference 3410 to step 3411, where a determination is made as to whether a DTMF digit sequence representing the Access Number 701 of the subscriber being called is detected by call processor 3300. If a valid phone number is not detected, then control remains at step 3411. If a valid phone number is detected, then control passes to step 3412 where a 2 second pause is initiated. Then at step 3413, the call processor 3300 dials the DTMF digit `*` to inform the CPF 100 that the connection has been successful so far. Control then passes to step 3414 where a determination is made as to whether the DTMF digit `d` is detected, indicating that the subscriber has called into the CPF 100, and the CPF 100 is about to conference him to the MMF 115. If the digit `d` is not detected then control remains at step 3414. If the digit `d` is detected, then control passes to step 3415 where a flash is generated on lines 120 causing the CENTREX system serving lines 120 to place the calling party (in this case the CPF 100) on hold, and a dial tone to be applied to line 120. Control then passes to step 3416 where a determination is made as to whether the subscriber has yet been connected to one of the other of lines 120 on the MMF 115. If the subscriber has not yet been connected, then control remains at step 3416. If it is determined that the subscriber has connected to one of the other of lines 120, then control passes to step 3417, where the CENTREX `barge-in code` (*77) is dialed by the DTMF generator of call processor 3300. Then at step 3418, the call processor 3300 dials the intercom code for the line 120 which is currently connected to the subscriber. Control then passes to step 3419 where a 2 second pause is generated, and then to step 3420 where a flash is generated. This causes the line 120 which is connected to the subscriber to be connected via the CENTREX system to the line 120 which is connected to the caller. Control then passes to step 3421 where control remains while the subscriber and caller converse, until a loop interruption signal is detected on line 120 indicating at least one of the two parties has disconnected. Control then passes to step 3432 where the line 120 is placed on hook, and control the returns to step 3401. If at step 3409 it is determined that the digit sequence `01` is detected, then control passes via a connector labelled "MMF SUBSCRIBER" at reference 3423 to step 3424, where a determination is made as to whether a DTMF digit sequence. representing the Access Number 701 of the subscriber is detected by call processor 3300. If a valid phone number is not detected, then control remains at step 3424. If a valid phone number is detected, then control passes to step 3425 where an indication is made available that a subscriber is connected to the MMF 115 on this line 120. Control then passes to step 3426 where a 3 second pause is initiated, allowing time for the line 120 connected to the subscriber to perform the barge-in sequence. Control then passes to step 3427 where the line 120 is placed on hook causing the CENTREX system to call transfer the subscriber to the line 120 which has just barged-in. Control then returns to step 3401.
A block diagram of the Subscriber Access Facility (SAF) 110 is illustrated in FIG. 35. The SAF 110 provides a means by which subscribers can access the Telephone Control System 1 via trunks which provide automatic number identification (ANI). SAF trunk interface 3500 interfaces the SAF 110 with trunks 8. The trunk interface 3500 is the same trunk interface as was described earlier at reference 400 used in the CPF 100, however the E & M Lead Control Circuit operates under a slightly different set of instructions, as will be described below in the explanation which accompanies FIG. 36. Still referring to FIG. 35, as was discussed earlier, the preferred embodiment of the TELEPHONE CONTROL SYSTEM 1 employs a Feature Group D (FGD) facility for trunks 8. This is provided via a 4-wire E&M trunk provisioned with TYPE I signaling, which is well known in the art. These type of trunks provide a 2-wire balanced transmit audio connection, a 2-wire balanced receive audio connection, an E-Lead, and an M-Lead. Although only one trunk interface 3500, one trunk 8, and one call processor 3504 are shown in FIG. 35, it should be readily evident to one skilled in the art that additional trunk interfaces and call processors may be added to support additional trunks. The trunk interface 3500 provides a two-way audio path shown at reference 3501, a loop status output shown at reference 3502, and a on/off hook control input shown at reference 3503. These lines are shown connected to call processor 3504 which performs the functions of voice storage and playback, DTMF generation and detection, and call control. Devices which perform the functions of call processor 3504 are well known in the art and many products, such as the Model D41B manufactured by Dialogic Corporation, exist commercially which can accomplish these functions. Also shown is a multi frequency detector module 3505 which is shown connected to the call processor 3504. A commercially available multi-frequency module capable of performing this function is the Model MF/40 manufactured by Dialogic Corporation. A data network interface 3507 is used to connect the SAF 110 to the other subsystems of the Telephone Control System 1. Data network interface 3507 passes data messages between the SAF 110 and these other subsystems. The functions of data network interface 3507 are well known in the art, and. many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. CPU 3506, which contains a microprocessor, a boot ROM, a RAM, and a disk, controls all functions of the SAF 110. The trunk interface 3500, the CPU 3506, the call processor 3504, and the data network interface 3507 are all shown connected to an internal data bus 3508. The CPU 3506 initializes itself at power-up using the boot ROM and then loads a control program into memory which it then executes. The control program allows for the control of simultaneous activities on the trunks 8. An explanation of the control program for the SAF 110 accompanies FIGS. 37a, 37b and 37b-1.
A flowchart of the operation of E&M control circuit for the trunk interface 3500 of the SAF 115 is shown in FIG. 36. As the construction of the trunk interface 3500 of FIG. 35 is identical to that of the trunk interface 400 of FIG. 5, the explanation which follows will refer to the reference numbers of FIG. 5 when discussing the internal components of the trunk interface 3500. Referring now to FIG. 36, the E&M Lead Control Circuit Operation for the SAF Trunk Interface function is entered at step 3600 and control passes to step 3601 where the control circuit 450 idles waiting for an indication from current detector 440 that the E-Lead has gone off-hook. When the E-Lead does go off-hook, control passes to step 3602 where an "Incoming Call" signal is sent to CPU 3506 via buffer 460. Control then passes to step 3603 where a determination is made as to whether an off-hook signal is received from call processor 3504 signifying that the CPU 3506 is ready to accept the call. If the off hook signal is detected, then control passes to step 3604 where the `loop status` 3502 is set active. Control then passes to step 3605 where the M-Lead is winked by taking the M-Lead relay 455 momentarily off-hook. Control then passes to step 3606 where a determination is made as to whether a `DID received` signal 480 is detected. If the signal is not detected then control remains at step 3606. If the signal is received, indicating that the multifrequency detector 3505 has detected the `ANI` and `called number` digits from the FGD trunk 8, then control passes to step 3607 where the M-lead relay is once more winked momentarily off hook to acknowledge receipt of the multifrequency data. A 300 millisecond pause is then initiated at step 3608, prior to taking the M-Lead off hook at 3609 to `answer` the trunk. At this point audio is established by the switch which is providing the FGD service, and the calling party is connected to the SAF 110. Control then passes to a loop consisting of steps 3610 and 3611. This loop persists until either at step 3610 the on/off hook signal 3503 is taken on hook by the call processor 3504, or at 3611 the E-Lead is determined to be on-hook. In either case the call is ended, and control passes to step 3612 where the `loop status` signal 3502 is set inactive. Then at step 3613 a determination is made as to whether the `DID received` signal 480 still remains active indicating the CPU 3506 is not yet ready to receive a new call. If this signal is still active, then control remains at step 3613. If it is determined at step 3613 that the `DID received` signal 480 is now inactive, then control passes to step 3614 where the M-Lead is placed on hook, terminating the call, and control passes to step 3601.
A flowchart of the Subscriber Access Facility Main Task is illustrated in FIGS. 37a, 37b and 37b-1. This program is loaded into memory and executed by SAF CPU 3506. The Subscriber Access Facility Main Task is entered at step 3700 and control passes to step 3701 where a `clear DID received` signal is sent to the trunk interface 3500. Control then passes to step 3702 where the `incoming call` signal of the trunk interface 3500 is checked. If this signal is not active then control remains at step 3702. If this signal is active, then control passes to step 3703, where the output of the multifrequency detector 3505 is checked via call processor 3504. The incoming multifrequency digit sequence `KP`+`00`+ANI+`ST` is decoded where `KP` is the start digit, `ST` is the stop digit, and the ANI is the phone number of the phone from which the subscriber is calling. Control then passes to step 3704 where, in a similar manner, the incoming multifrequency digit sequence `KP`+800+NXX+XXXX+`ST` is decoded. Again the `KP` is the start digit, the `ST` is the stop digit, and the sequence 800 NXX XXXX is the phone number dialed by the subscriber to reach the trunk 8, the NXX being the prefix which identifies trunk group 8 to the PSTN 2. This phone number represents the programming function which the subscriber wishes to accomplish. Control then passes to step 3705 where a `set DID received` signal is sent to the trunk interface 3500, indicating that the multifrequency data has been received. Control then passes to step 3706 where a determination is made as to whether the dialed number was of the form 800-NXX-00ab, and if the dialed number was not of this form then control passes to a connector labelled "SAF EXT" at reference 3707. If at step 3706 it is determined that the dialed number is of the form 800-NXX-00ab, then control passes to step 3710 where a `request master record` message is constructed using the ANI received in step 3703, and the message is sent via data network interface 3507 to the CPF 100. Control then passes to step 3711 where a determination is made as to whether a response has been received to the `request master record` message, and if such a response is not received control remains at step 3711. If the response message is received by network interface 3507, then control passes to step 3712 where a determination is made as to whether a valid subscriber master record 700 is included in the returned message. If a valid subscriber master record is not included, then control passes to the connector labelled "SAF REORDER" shown at reference 3713. If at step 3712 a valid subscriber master record 700 is found, then control passes to step 3714 where the DID number 701 is removed from the subscriber master record 700. Control then passes to step 3715 where a `mode memory inquiry` message is constructed using the DID number 701 and the digits `ab` as detected in step 3706, and the message is sent via data network interface 3507 to the CPF 100. Control then passes to step 3716 where a determination is made as to whether a response has been received to `mode memory inquiry` message, and if such a response is not received control remains at step 3716. If the response message is received by network interface 3507, then control passes to step 3717 where a determination is made as to whether a valid mode memory 800 is included in the returned message. If a valid mode memory 800 is not included, then control passes to the connector labelled "SAF REORDER" shown at reference 3718. If at step 3717 a valid mode memory 800 is found, then control passes to step 3720, which is identified by a connector labelled "SAF UPDATE" at reference 3719. At step 3720 a `change to new mode memory` message is constructed, again using DID number 701 and the digits `ab` as detected in step 3706, and the message is sent via data network interface 3507 to the CPF 100. Control then passes to step 3721 where the subscriber is prompted by call processor 3504: "Accepted, you have selected mode memory . . . `ab`", where `ab` are the digits detected in step 3706. Control then passes to step 3722 where the call processor 3504 causes trunk 8 to be placed on hook, and then control returns to step 3701. If at step 3706 it is determined that the dialed number was not of the form `800-NXX-00ab`, then control passes to a connector labelled "SAF EXT" as shown at reference 3707. A connector labelled "SAF EXT" is shown at reference 3724, which causes control to be passed to step 3725 where a determination is made as to whether the dialed number was of the form 800-NXX-cdef, where the digits `cd` do not equal `00`. If the dialed number is not of this form, then control passes to a connector labelled "SAF REORDER" shown at reference 3745. If at step 3725 it is determined that the dialed number is of this form, then control passes to step 3726 where call processor 3504 prompts the subscriber by playing a `bong tone`. Control then passes to step 3727 where a determination is made as to whether the subscriber has entered a PIN code, and if the PIN code is not entered control remains at step 3727. If a PIN code is entered, then control passes to step 3728 where a `request master record` message is constructed using then PIN code entered in step 3727 and the digits `cdef` detected in step 3706. This message is then sent via data network interface 3507 to the CPF 100. Control then passes to step 3729 where a determination is made as to whether a response has been received to the `request master record` message, and if such a response is not received control remains at step 3729. If the response message is received by network interface 3507, then control passes to step 3750 where a determination is made as to whether a valid subscriber master record 700 is included in the returned message. If a valid subscriber master record is not included, then control passes to the connector labelled "SAF REORDER" shown at reference 3751. If at step 3750 a valid subscriber master record 700 is found, then this indicates that CPF 100 found a subscriber master record 700 which had a DID number 701 which had the same last four digits as the digits `cdef` detected in step 3706, and also had the same PIN code 702 as that detected in step 3727. Control passes to step 3730 where the subscriber is prompted: "Please enter your new mode memory number." Control then passes to step 3731 where a determination is made as to whether the subscriber has entered a memory number `10 to `99`, and if such a number has not been entered, then control remains at step 3731. If a mode memory number is entered, then control passes to step 3732 where a `mode memory inquiry` message is constructed using the DID number 701 and the and the memory number as detected in step 3731, and the message is sent via data network interface 3507 to the CPF 100. Control then passes to step 3733 where a determination is made as to whether a response has been received to the `mode memory inquiry` message, and if such a response is not received control remains at step 3733. If the response message is received by network interface 3507, then control passes to step 3734 where a determination is made as to whether a valid mode memory 800 is included in the returned message. If a valid mode memory 800 is not included, then control passes to the connector labelled "SAF REORDER" shown at reference 3745. If at step 3734 a valid mode memory 800 is found, then control passes to step 3735, where a determination is made as to whether the mode memory which was received in the message requires an `externally entered` memory. This is determined by inspecting the transfer number field of the mode memory 800. If it has an `externally entered number` tag, then the mode memory does require an `externally entered number`. If at step 3735 it is determined that an `externally entered number` is not required, then control passes to a connector labelled "SAF UPDATE" at reference 3736, which as described earlier causes the mode memory requested to be invoked. If at step 3735 it is determined that an `externally entered number` is required, then control passes to step 3737 where the subscriber master record 700 as acquired at step 3750 is retrieved from memory. Control then passes to step 3738 where the mode memory 800 that was acquired in step 3734 is copied field-by-field to the subscriber master record. Control then passes to step 3740, where the ANI number acquired in step 3703 is copied to the transfer number field 707 of the subscriber master record 700. Control then passes to step 3741 where an `update master record` message is constructed using this master record, and the message is sent via data network interface 3507 to CPF 100. Control then passes to step 3742 where the subscriber is prompted: "Accepted, you have selected mode memory . . . xx", where the digits `xx` are the digits entered by the subscriber at step 3731. Control then passes to step 3743 Where the trunk 8 is placed on hook, and then control returns to the Subscriber Access Facility Main Task entry point as shown at reference 3748. If at step 3734, it is determined that the mode memory received in the message was not valid, then control passes to a connector labelled "SAF REORDER" at reference 3745, which causes control to pass to step 3746 where the call processor 3504 plays a `reorder signal` to the subscriber, indicating that the call is being terminated. Control then passes to step 3747 where the trunk 8 is placed on hook. Control then returns to the Subscriber Access Facility Main Task entry point as shown at reference 3748.
A block diagram of the Communicator Access Facility (CAF) 125 is illustrated in FIG. 38. As shown, the CAF 125 contains a serial port interface module 3800 which connects to the serial datalink 10, and a data network interface 3801 which connects to the high speed data network 150. The functions of data network interface 3801 are well known in the art, and many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. The operation of the CAF 125 is controlled by CPU module 3802, which consists of a microprocessor, a boot ROM, RAM, and disk. The boot ROM is used to initialize the CPU and load the control program into memory from disk. Operation of the CAF 125 is then controlled by the control program. The control program is described in the explanation which accompanies FIG. 39. Still referring to FIG. 38, the serial port 3800, data network interface 3801, and the CPU module 3802 are all shown connected to internal bus 3803.
A flowchart of the Communicator Access Facility Main Task is illustrated in FIG. 39. This program is loaded into memory and executed by CPU 3802 of the CAF 125. The Communicator Access Facility Main Task is entered at step 3900 and control passes to step 3901 where a determination is made as to whether a `page message` is received via data network interface 3801, and if a `page message` is received then control passes to step 3902 where the page message is sent via serial port 3800 and datalink 10 to packet radio transceiver 9. Control then passes to step 3903 where an `acknowledge timer` is started, and the `page message` just sent is saved and associated with this `acknowledge timer`. Control then passes to step 3904. Control also passes to step 3904 if a `page message` is not received as determined at step 3901. At step 3904, a determination is made as to whether a `phone number` message has been received from a communicator 11 via the serial port interface 3800. If such a message has been received, then control passes to step 3905 where the subscriber's DID number 701 is retrieved form the message, and a `request master record` message is created and sent to the CPF 100 via data network interface 3801. When the response is received from the CPF 100 via the data network interface 3801, the subscriber master record is retrieved from the response message. Control then passes to step 3906 where the transfer number field 707 of the subscriber master record 700 is updated per the phone number received from the communicator 11 at step 3904. Control then passes to step 3907 where an `update master record` message is then constructed and sent back to the CPF 100 via data network interface 3801. Control then passes to step 3908, where an `acknowledge message` is sent back to the communicator 11 via serial port 3800. Control then passes to step 3909. Control also passes to step 3909 if a `phone number` message is not detected at step 3904. At step 3909 a determination is made as to whether a `new mode memory` message is received from a communicator 11 via serial port 3800. If this message type has been received then control passes to step 3910 where a `change to new mode memory` message is constructed and sent to CPF 100 via data network interface 3801, and then control passes to step 3908 where an `acknowledge` message is sent back to the communicator 11 as described earlier. If at step 3909 a `new mode memory request` message is not detected, then control passes to step 3911 where a determination is made as to whether a `set dynamic mode assignment mode` message is received from a communicator 11 via serial port 3800. If this message type is received, then control passes to step 3912, where a `set dynamic mode assignment flag` message is constructed and sent to CPF 100 via data network interface 3801. Control then passes to step 3908 where an `acknowledge` message is sent back to the communicator 11 as described earlier. If at step 3911 a `set dynamic mode assignment mode` message is not detected, then control passes to step 3913 where a determination is made as to whether a `disable dynamic mode assignment mode` message is received from a communicator 11 via serial port 3800. If this message type is received, then control passes to step 3914, where a `clear dynamic mode assignment flag` message is constructed and sent to CPF 100 via data network interface 3801. Control then passes to step 3908 where an `acknowledge` message is sent back to the communicator 11 as described earlier. If at step 3913 a `disable dynamic mode assignment mode` message is not detected, then control passes to step 3915 where a determination is made as to whether the `acknowledge timer` has just expired. If the `acknowledge timer` has just expired, as determined at step 3915, then control passes to step 3916 where the message which was associated with this `acknowledge timer` is again sent to the communicator 11 via serial port interface 3800, and control then passes to step 3903. If at step 3915 it is determined that an `acknowledge timer` has not just expired, then control passes to step 3917 where a determination is made as to whether an `acknowledge` message is received from a communicator via serial port interface 3800, and if an `acknowledge` message is not received, then control returns to step 3901. If an `acknowledge` message is received, as determined at step 3917, then the `acknowledge` timer which is associated with the last message sent to the communicator 11 identified in the `acknowledge` message is cleared. Control then returns to step 3901.
A flowchart of the Communicator Main Task is illustrated in FIGS. 40 and 40a.` This task is executed by microprocessor 200, and controls all operations of the communicator 11. The Communicator Main Task is entered at step 4000 and control passes to step 4001 where a determination is made as to whether a `page` message is detected at the receive data input 245. If a `page` message is detected, and the message contains the pager number which corresponds to this communicator, then control passes to step 4002, where a signal is sent via output port 250 causing the beeper 260 to generate an alerting sound. Control then passes to step 4003 where a display number is retrieved from the decoded `page` message, and is output to the display 210. Control then passes to step 4004 where a brief `acknowledge` message is sent via transmit data port 215 to packet data encoder 220 and then to rf transmitter 225. All RF transmissions from communicator 11 are sent as brief packet `bursts`, thus maintaining a longer life for battery 290. Control then returns to step 4001. If at step 4001 it is determined that a `page` message is not received, then control passes to step 4005 where a determination is made as to whether a `manual phone number flag` is set, and if the flag is not set control passes to step 4006 where a determination is made as to whether a data message is received from the ultrasonic transmitter 12 via the serial data input 280, and if such a message is received then control passes to step 4007. At step 4007 a determination is made as to whether a `auto phone number flag` is set and if the flag is not set control passes to step 4009 where the `auto phone number flag` is set. Control then passes to step 4010 where the phone number which was embedded in the message received at step 4006 is stored in the memory of microprocessor 200. Control then passes to step 4011 where a `phone number` message is constructed using the phone number of step 4006, and the subscriber DID number 701, as prestored in the RAM of microprocessor 200. This message is then sent to transmit data port 215. Control then passes to step 4012 where an `acknowledge timer` is started. Control then passes to step 4013 where a `20 second ultrasonic data timer` is started. Control then returns to step 4001. If at step 4007 it is determined that the `auto phone number flag` is set, then control passes to step 4008, where a determination is made as to whether the phone number received embedded in the message at step 4006 is the same as the phone number currently in memory as stored at step 4010. If the phone numbers match then control passes to step 4013. If at step 4008 it is determined that the phone numbers are different, indicating that the subscriber has moved to a different room, then control passes to step 4009. If at step 4005 it is determined that the `manual phone number flag` is set, or if at step 4006 it is determined that a data message is not being received via input port 280, then control passes to step 4014 where a determination is made as to whether the `20 second ultrasonic data timer` has just expired, and if it has, indicating that the subscriber is no longer near an ultrasonic transmitter 12, then control passes to step 4015. At step 4015 the `auto phone number flag` is cleared and control passes to step 4016 where the a `new mode memory request` message is constructed using the stored subscriber DID number 701, and the stored `default mode memory`. Control then passes to step 4017 where an `acknowledge timer` is started, and then control returns to step 4001. If at step 4014 it is determined that the `20 second ultrasonic data timer` has not just expired, then control passes to step 4018 where a determination is made as to whether the `acknowledge timer` has just expired, and if it has just expired control passes to step 4019 where the message is re-sent via transmit data port 215. Then at step 4020, an `acknowledge timer` is started, and then control returns to step 4001. If at step 4018 it is determined that the `acknowledge timer` has not expired, then control passes to step 4021 where a determination is made as to whether an `acknowledge` message with a pager number that corresponds to this communicator 11 is received via the receive data input 245, and if such a message is received then control passes to step 4022 where the `acknowledge timer` is cleared. Control the returns to step 4001. If at step 4021 it is determined that an `acknowledge` message is not received, then control passes to step 4023 where a determination is made as to whether the subscriber is entering data via the keypad 205, and if the subscriber is not entering data, then control returns to step 4001. If the subscriber is entering data via the keypad, as determined at step 4023, then control passes to step 4024 where a determination is made as to whether the subscriber wishes to program the Telephone Control System 1 to operate under control of a new mode memory. If this is the case, then control passes to step 4025 where a `new mode memory request message` is constructed and sent to transmit data port 215, and then control passes to step 4033 where an `acknowledge timer` is started, and then control returns to step 4001. If at step 4024 it is determined that the subscriber is not selecting a new mode memory, then control passes to step 4026 where a determination is made as to whether the subscriber is selecting the dynamic mode assignment feature, and if this is the case, then control passes to step 4027 where a `set dynamic mode assignment mode` message is constructed and sent to transmit data port 215, and then control passes to step 4033. If at step 4026 it is determined that the subscriber is not selecting the dynamic mode assignment feature, then control passes to step 4028 where a determination is made as to whether the subscriber is disabling the dynamic mode assignment feature, and if this is the case, then control passes to step 4029 where a `disable dynamic mode assignment mode` message is constructed and sent to transmit data port 215, and then control passes to step 4033. If at step 4028 it is determined that the subscriber is not disabling the dynamic mode assignment mode, then control passes to step 4030 where a determination is made as to whether the subscriber is entering a phone number, and if a phone number is being entered then control passes to step 4031 where the `manual phone number flag` is set. Control then passes to step 4032 where a `phone number` message is constructed using the phone number entered by the subscriber at step 4030, and this message is transmitted via transmit data port 215. Control then passes to step 4033. If at step 4030 it is determined that the subscriber is not entering a phone number, then control. passes to step 4034 where a determination is made as to whether the subscriber is selecting the auto-phone number mode, and if this is the case, then control passes to step 4035 where the `manual phone number flag` is cleared, and control then passes to step 4015. If at step 4034 it is determined that the subscriber is not selecting the auto-phone number mode, then control passes to step 4036, where a determination is made as to whether the subscriber is entering new program data such a the stored DID number, the stored pager number, and the stored default mode memory. If the subscriber is attempting to modify any of these parameters, then control passes to step 4037 where the new data is stored in the RAM of microprocessor 200. Otherwise, control returns to step 4001. As can be understood from the explanation above, one of the primary functions of the Communicator 11 and the Communicator Access Facility 125 is to take the phone number identifying the location of the subscriber, as transmitted by ultrasonic transmitter 12, and cause that number to be used by the Telephone Control System 1 as the forwarding number for the subscriber. It should also be understood that in a similar fashion the ultrasonic transmitter 12 may transmit a `mode memory number` which, if sent to the Telephone Control System 1 via the Communicator 11 and the Communicator Access Facility 125, would allow that mode memory to be used by the Telephone Control System 1 to specify the call handling mode for the subscriber. In this case, the Communicator 11 receives a data message from an ultrasonic transmitter 12 and determines that the message contains a mode memory. The Communicator 11 then transmits a `new mode memory request` message, which includes the subscriber's DID number 701, via its RF transmitter 225. This message is received by packet radio transceiver 9 and sent to the CAF 125 via data line 10. The CAF 125 then sends a "change to new mode memory" message to CPF 100 via data network interface 3801. CPF 100 then copies the mode memory referred to in the message to this subscriber's "subscriber master record" 700. To further illustrate this process, consider the example of a hospital operating room where an ultrasonic transmitter 12 is transmitting a message containing a mode memory number which corresponds to the "message center" call handling mode. If a doctor, carrying a Communicator 11 enters the operating room, then the Telephone Control System is automatically programmed to send his calls to the "message center."
A block diagram of the Pager Dialing Facility (PDF) 105 is illustrated in FIG. 41. Standard tip-ring line 5 is shown connected to call processor 4100, which contains a tip-ring interface, DTMF generators, call progress detectors. The functions of call processor 4100 are well known in the art, and many products, such as the Model D41B manufactured by Dialogic Corporation, exist commercially which can accomplish these functions. The PDF 105 also contains a CPU 4101 which contains a microprocessor, a boot ROM, a RAM, and a disk. The PDF 105 also contains a data network interface module 4103 which connects to the high speed data network 150. The functions of data network interface 4103 are well known in the art, and many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. The call processor 4100, the CPU 4101, and the data network interface 4103 are all shown connected to an internal data bus 4102. The CPU 4101 initializes itself at power-up using the boot ROM and then loads a control program into memory which it then executes.
A flowchart of the Pager Dialing Facility Main Task is illustrated in FIG. 42. This program is loaded into memory and executed by CPU 4101 of the PDF 105. The Pager Dialing Facility Main Task is entered at step 4200 and control passes to step 4201 where a determination is made as to whether a `page` message is received from CPF 100 via data network interface 4201, and if the message is not received then control remains at step 4201. If a `page` message is received, then the `pager number` and the `display digits` are retrieved from the message, and control passes to step 4202 where an `attempt count` is set to a value of 1. Control then passes to step 4203, where line 5 is taken off hook, and then control passes to step 4204 where call processor 4100 dials the `pager number`. Control then passes to step 4205 where a determination is made as to whether the call has not been answered due to a time-out or a non-answer signal such as operator intercept, busy, or reorder. If such a signal or time-out condition is not detected then control passes to step 4206 where a determination is made as to whether the call has been answered by the paging terminal, and if the call has not been answered, control returns to step 4205. If at step 4206 it is determined that the call is answered, then control passes to step 4207 where a 1 second pause is initiated, and then control passes to step 4208 where the `display digits` are dialed by call processor 4100. Control then passes to step 4209 where the pager termination digit `#` is dialed, and then control passes to step 4210 where the line 5 is placed on hook. Control then passes to step 4211 where a 2 second delay is initiated before returning control to step 4201. If at step 4205 it is determined that a time-out or non-answer signal is detected, then control passes to step 4212 where the `attempt count` is incremented. Control then passes to step 4213 where the `attempt count` is checked and if it is found to be not equal to ten then control passes to step 4214 where the line 5 is placed on hook and then after a 2 second pause a step 4215, control returns to step 4203 to make another attempt at dialing this number. If at step 4213 it is found that the `attempt count` is now equal to 10, then this page is abandoned by returning control to step 4201.
A block diagram of the Client Services Facility (CSF) 130 is illustrated in FIG. 43. The Client Services Facility (CSF) 130 is used by the service bureau which provides the Telephone Control System service to it's subscribers. The CSF 130 allows a client services representative to gain access to the database contained in the CPF 100, and thus be able to review and modify the subscriber master records 700 and mode memories 800 of the subscribers. The CSF 130 contains a CPU 4300 which contains a microprocessor, a boot ROM, a RAM, and a disk. The CSF 130 also contains a data network interface module 4301 which connects to the high speed data network 150. The functions of data network interface 4301 are well known in the art, and many products, such as the Model COM4i from Digiboard Corporation, exist commercially which can accomplish these functions. Also shown is a display monitor 4302, and a keyboard 4303. The CPU 4300 initializes itself at power-up using the boot ROM and then loads a control program into memory which it then executes.
A flowchart of the Client Services Facility Main Program is illustrated in FIG. 44. This program is loaded into memory and executed by CPU 4300 of the CSF 130. The Client Services Facility Main Program is entered at step 4400 and control passes to step 4401 where a determination is made as to whether the client services representative has entered the DID number for a particular subscriber and has requested a subscriber master record 700, and if this is the case then control passes to step 4402 where a `request master record` message is sent via data network interface 4301 to CPF 100. Control then passes to step 4403 where the subscriber master record 700 is removed from the response message from the CPF 100, and is displayed on monitor 4302. Then at step 4404, the client services representative is allowed to review and modify the contents of the subscriber master record 700 using monitor 4302 and keyboard 4303. Then at step 4405 a determination is made as to whether the client services representative is completed with this operation, and if not, then control returns to step 4404. When the operation is complete, then control passes to step 4406 where an `update master record` message is constructed and sent to CPF 100 via data network interface 4301. Control then returns to step 4401. If at step 4401 it is determined that the client services representative is not requesting a subscriber master record 700, then control passes to step 4407 where a determination is made as to whether the client services representative has entered the DID number for a particular subscriber and has requested a subscriber mode memory 800, and if this is the case then control passes to step 4408 where a `mode memory inquiry` message is sent via data network interface 4301 to CPF 100. Control then passes to step 4409 where the mode memory 800 is removed from the response message from the CPF 100, and is displayed on monitor 4302. Then at step 4410, the client services representative is allowed to review and modify the contents of the mode memory 800 using monitor 4302 and keyboard 4303. Then at step 4411 a determination is made as to whether the client service representative is completed with this operation, and if not, then control returns to step 4410. When the operation is complete, then control passes to step 4412 where an `update mode memory` message is constructed and sent to CPF 100 via data network interface 4301. Control then returns to step 4401. If at step 4407 it is determined that the client services representative is not requesting a new mode memory, the control passes to step 4413 where a determination is made as to whether the client services representative has entered a DID number and wishes to activate a new subscriber for this number. If this is the case then control passes to step 4414 where a `create a new subscriber message` is generated with this DID number and the message is sent to CPF 100 via data network interface 4301. Control then returns to step 4401. If at step 4413 it is determine that the client services representative does not wish to create a new subscriber, then control returns to step 4401.
While a preferred embodiment of the invention has been described in detail it should be apparent that many modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention.
For example, while the preferred embodiment of the control system provides voice synthesized type courtesy messages, any appropriate tones, beeps, etc. would serve as a courtesy message and such is the use of that term throughout the claims appended hereto. In addition, the term "line" as used herein and in the claims appended hereto includes both lines and trunks.
In addition, whereas the preferred embodiment of the invention uses the term "line" to describe the interconnecting medium between the control system and the central exchange, it should be understood throughout the specification and claims that "line" refers to tip and ring pairs, trunks or any other form of connecting circuits. | The invention provides a apparatus and method for processing incoming telephone calls directed to a user. Incoming telephone calls have certain status information which is generated by the call processor. A transmitter is utilized for transmitting pages to a paging devices carried by users. The paging devices have a display device associated with them and the transmitted page includes the status information associated with an incoming call for display on the display of th paging device. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. application Ser. No. 13/933,623, filed Jul. 2, 2013, which is a Continuation of U.S. application Ser. No. 13/548,446, filed Jul. 13, 2012, which is a Continuation of U.S. application Ser. No. 12/334,731, filed Dec. 15, 2008, which claims priority from U.S. Provisional Patent Application 61/014,232, filed Dec. 17, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to a process for producing prostacyclin derivatives and novel intermediate compounds useful in the process.
[0003] Prostacyclin derivatives are useful pharmaceutical compounds possessing activities such as platelet aggregation inhibition, gastric secretion reduction, lesion inhibition, and bronchodilation.
[0004] Treprostinil, the active ingredient in Remodulin®, was first described in U.S. Pat. No. 4,306,075. Treprostinil, and other prostacyclin derivatives have been prepared as described in Moriarty, et al in J. Org. Chem. 2004, 69, 1890-1902 , Drug of the Future, 2001, 26(4), 364-374, U.S. Pat. Nos. 6,441,245, 6,528,688, 6,765,117 and 6,809,223. Their teachings are incorporated by reference to show how to practice the embodiments of the present invention.
[0005] U.S. Pat. No. 5,153,222 describes use of treprostinil for treatment of pulmonary hypertension. Treprostinil is approved for the intravenous as well as subcutaneous route, the latter avoiding septic events associated with continuous intravenous catheters. U.S. Pat. Nos. 6,521,212 and 6,756,033 describe administration of treprostinil by inhalation for treatment of pulmonary hypertension, peripheral vascular disease and other diseases and conditions. U.S. Pat. No. 6,803,386 discloses administration of treprostinil for treating cancer such as lung, liver, brain, pancreatic, kidney, prostate, breast, colon and head-neck cancer. U.S. patent application publication No. 2005/0165111 discloses treprostinil treatment of ischemic lesions. U.S. Pat. No. 7,199,157 discloses that treprostinil treatment improves kidney functions. U.S. patent application publication No. 2005/0282903 discloses treprostinil treatment of neuropathic foot ulcers. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008, discloses treprostinil treatment of pulmonary fibrosis. U.S. Pat. No. 6,054,486 discloses treatment of peripheral vascular disease with treprostinil. U.S. patent application Ser. No. 11/873,645 filed Oct. 17, 2007 discloses combination therapies comprising treprostinil. U.S. publication No. 2008/0200449 discloses delivery of treprostinil using a metered dose inhaler. U.S. publication No. 2008/0280986 discloses treatment of interstitial lung disease with treprostinil. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008 discloses treatment of asthma with treprostinil. U.S. Pat. Nos. 7,417,070, 7,384,978 and U.S. publication Nos. 2007/0078095, 2005/0282901, and 2008/0249167 describe oral formulations of treprostinil and other prostacyclin analogs.
[0006] Because Treprostinil, and other prostacyclin derivatives are of great importance from a medicinal point of view, a need exists for an efficient process to synthesize these compounds on a large scale suitable for commercial production.
SUMMARY
[0007] The present invention provides in one embodiment a process for the preparation of a compound of formula I, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof.
[0000]
[0008] The process comprises the following steps:
[0009] (a) alkylating a compound of structure II with an alkylating agent to produce a compound of formula III,
[0000]
[0010] wherein
w=1, 2, or 3; Y 1 is trans-CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 1 S (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )—R 2 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3-thienyloxymethyl; M 1 is α-OH:β-R 5 or α-R 5 :β-OH or α-OR 2 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro.
[0027] (b) hydrolyzing the product of step (a) with a base,
[0028] (c) contacting the product of step (b) with a base B to for a salt of formula I s
[0000]
[0029] (d) reacting the salt from step (c) with an acid to form the compound of formula I.
[0030] The present invention provides in another embodiment a process for the preparation of a compound of formula IV.
[0000]
[0031] The process comprises the following steps:
[0032] (a) alkylating a compound of structure V with an alkylating agent to produce a compound of formula VI,
[0000]
[0033] (b) hydrolyzing the product of step (a) with a base,
[0034] (c) contacting the product of step (b) with a base B to for a salt of formula IV s , and
[0000]
[0035] (d) reacting the salt from step (b) with an acid to form the compound of formula IV.
DETAILED DESCRIPTION
[0036] The various terms used, separately and in combinations, in the processes herein described are defined below.
[0037] The expression “comprising” means “including but not limited to.” Thus, other non-mentioned substances, additives, carriers, or steps may be present. Unless otherwise specified, “a” or “an” means one or more.
[0038] C 1-3 -alkyl is a straight or branched alkyl group containing 1-3 carbon atoms. Exemplary alkyl groups include methyl, ethyl, n-propyl, and isopropyl.
[0039] C 1-3 -alkoxy is a straight or branched alkoxy group containing 1-3 carbon atoms. Exemplary alkoxy groups include methoxy, ethoxy, propoxy, and isopropoxy.
[0040] C 4-7 -cycloalkyl is an optionally substituted monocyclic, bicyclic or tricyclic alkyl group containing between 4-7 carbon atoms. Exemplary cycloalkyl groups include but not limited to cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
[0041] Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein.
[0042] As used herein, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide an active compound. Examples of prodrugs include, but are not limited to, derivatives of a compound that include biohydrolyzable groups such as biohydrolyzable amides, biohydrolyzable esters, biohydrolyzable carbamates, biohydrolyzable carbonates, biohydrolyzable ureides, and biohydrolyzable phosphate analogues (e.g., monophosphate, diphosphate or triphosphate).
[0043] As used herein, “hydrate” is a form of a compound wherein water molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
[0044] As used herein, “solvate” is a form of a compound where solvent molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
[0045] “Pharmaceutically acceptable” means in the present description being useful in preparing a pharmaceutical composition that is generally safe, non-toxic and neither biologically nor otherwise undesirable and includes being useful for veterinary use as well as human pharmaceutical use.
[0046] “Pharmaceutically acceptable salts” mean salts which are pharmaceutically acceptable, as defined above, and which possess the desired pharmacological activity. Such salts include acid addition salts formed with organic and inorganic acids, such as hydrogen chloride, hydrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, glycolic acid, maleic acid, malonic acid, oxalic acid, methanesulfonic acid, trifluoroacetic acid, fumaric acid, succinic acid, tartaric acid, citric acid, benzoic acid, ascorbic acid and the like. Base addition salts may be formed with organic and inorganic bases, such as sodium, ammonia, potassium, calcium, ethanolamine, diethanolamine, N-methylglucamine, choline and the like. Included in the invention are pharmaceutically acceptable salts or compounds of any of the formulae herein.
[0047] Depending on its structure, the phrase “pharmaceutically acceptable salt,” as used herein, refers to a pharmaceutically acceptable organic or inorganic acid or base salt of a compound. Representative pharmaceutically acceptable salts include, e.g., alkali metal salts, alkali earth salts, ammonium salts, water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosalicylate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts.
[0048] The present invention provides for a process for producing treprostinil and other prostacyclin derivatives and novel intermediate compounds useful in the process. The process according to the present invention provides advantages on large-scale synthesis over the existing method. For example, the purification by column chromatography is eliminated, thus the required amount of flammable solvents and waste generated are greatly reduced. Furthermore, the salt formation is a much easier operation than column chromatography. Moreover, it was found that the product of the process according to the present invention has higher purity. Therefore the present invention provides for a process that is more economical, safer, faster, greener, easier to operate, and provides higher purity.
[0049] One embodiment of the present invention is a process for the preparation of a compound of formula I, or a hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof
[0000]
[0050] The process comprises the following steps:
[0051] (a) alkylating a compound of formula II with an alkylating agent to produce a compound of formula III,
[0000]
[0052] wherein
w=1, 2, or 3; Y 1 is trans —CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 is (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )-R 2 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3-thienyloxymethyl; M 1 is α-OH:β-R 5 or α-R 5 :β-OH or α-OR 2 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro.
[0069] (b) hydrolyzing the product of step (a) with a base,
[0070] (c) contacting the product of step (b) with a base B to for a salt of formula I s
[0000]
[0071] (d) reacting the salt from step (c) with an acid to form the compound of formula I.
[0072] In one embodiment, the compound of formula I is at least 90.0%, 95.0%, 99.0%.
[0073] The compound of formula II can be prepared from a compound of formula XI, which is a cyclization product of a compound of formula X as described in U.S. Pat. No. 6,441,245.
[0000]
Wherein n is 0, 1, 2, or 3.
[0074] The compound of formula II can be prepared alternatively from a compound of formula XIII, which is a cyclization product of a compound of formula XII as described in U.S. Pat. No. 6,700,025.
[0000]
[0075] One embodiment of the present invention is a process for the preparation of a compound having formula IV, or a hydrate, solvate, or pharmaceutically acceptable salt thereof
[0000]
[0076] The process comprises
[0077] (a) alkylating a compound of structure V with an alkylating agent such as ClCH 2 CN to produce a compound of formula VI,
[0000]
[0078] (b) hydrolyzing the product of step (a) with a base such as KOH,
[0079] (c) contacting the product of step (b) with a base B such as diethanolamine to for a salt of the following structure, and
[0000]
[0080] (d) reacting the salt from step (b) with an acid such as HCl to form the compound of formula IV.
[0081] In one embodiment, the purity of compound of formula IV is at least 90.0%, 95.0%, 99.0%, 99.5%.
[0082] In one embodiment, the process further comprises a step of isolating the salt of formula IV s .
[0083] In one embodiment, the base B in step (c) may be ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, or triethanolamine.
[0084] The following abbreviations are used in the description and/or appended claims, and they have the following meanings:
[0085] “MW” means molecular weight.
[0086] “Eq.” means equivalent.
[0087] “TLC” means thin layer chromatography.
[0088] “HPLC” means high performance liquid chromatography.
[0089] “PMA” means phosphomolybdic acid.
[0090] “AUC” means area under curve.
[0091] In view of the foregoing considerations, and specific examples below, those who are skilled in the art will appreciate that how to select necessary reagents and solvents in practicing the present invention.
[0092] The invention will now be described in reference to the following Examples. These examples are not to be regarded as limiting the scope of the present invention, but shall only serve in an illustrative manner.
EXAMPLES
Example 1
Alkylation of Benzindene Triol
[0093]
[0000]
Name
MW
Amount
Mol.
Eq.
Benzindene Triol
332.48
1250 g
3.76
1.00
K 2 CO 3 (powder)
138.20
1296 g
9.38
2.50
CICH 2 CN
75.50
567 g
7.51
2.0
Bu 4 NBr
322.37
36 g
0.11
0.03
Acetone
—
29 L
—
—
Celite ®545
—
115 g
—
—
[0094] A 50-L, three-neck, round-bottom flask equipped with a mechanical stirrer and a thermocouple was charged with benzindene triol (1250 g), acetone (19 L) and K 2 CO 3 (powdered) (1296 g), chloroacetonitrile (567 g), tetrabutylammonium bromide (36 g). The reaction mixture was stirred vigorously at room temperature (23±2° C.) for 16-72 h. The progress of the reaction was monitored by TLC. (methanol/CH 2 Cl 2 ; 1:9 and developed by 10% ethanolic solution of PMA). After completion of reaction, the reaction mixture was filtered with/without Celite pad. The filter cake was washed with acetone (10 L). The filtrate was concentrated in vacuo at 50-55° C. to give a light-brown, viscous liquid benzindene nitrile. The crude benzindene nitrile was used as such in the next step without further purification.
Example 2
Hydrolysis of Benzindene Nitrile
[0095]
[0000]
Name
MW
Amount
Mol.
Eq.
Benzindene Nitrile
371.52
1397 g*
3.76
1.0
KOH
56.11
844 g
15.04
4.0
Methanol
—
12 L
—
—
Water
—
4.25 L
—
—
*Note: This weight is based on 100% yield from the previous step. This is not isolated yield.
[0096] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of benzindene nitrile in methanol (12 L) and a solution of KOH (844 g of KOH dissolved in 4.25 L of water). The reaction mixture was stirred and heated to reflux (temperature 72.2° C.). The progress of the reaction was monitored by TLC (for TLC purpose, 1-2 mL of reaction mixture was acidified with 3M HCl to pH 1-2 and extracted with ethyl acetate. The ethyl acetate extract was used for TLC; Eluent: methanol/CH 2 Cl 2 ; 1:9, and developed by 10% ethanolic solution of PMA). After completion of the reaction (˜5 h), the reaction mixture was cooled to −5 to 10° C. and quenched with a solution of hydrochloric acid (3M, 3.1 L) while stirring. The reaction mixture was concentrated in vacuo at 50-55° C. to obtain approximately 12-14 L of condensate. The condensate was discarded.
[0097] The aqueous layer was diluted with water (7-8 L) and extracted with ethyl acetate (2×6 L) to remove impurities soluble in ethyl acetate. To aqueous layer, ethyl acetate (22 L) was added and the pH of reaction mixture was adjusted to 1-2 by adding 3M HCl (1.7 L) with stirring. The organic layer was separated and the aqueous layer was extracted with ethyl acetate (2×11 L). The combined organic layers were washed with water (3×10 L) and followed by washing with a solution of NaHCO 3 (30 g of NaHCO 3 dissolved in 12 L of water). The organic layer was further washed with saturated solution of NaCl (3372 g of NaCl dissolved in water (12 L)) and dried over anhydrous Na 2 SO 4 (950-1000 g), once filtered.
[0098] The filtrate was transferred into a 72-L reactor equipped with mechanical stirrer, a condenser, and a thermocouple. To the solution of treprostinil in reactor was added activated carbon (110-130 g). The suspension was heated to reflux (temperature 68-70° C.) for at least one hour. For filtration, a pad of Celite® 545 (300-600 g) was prepared in sintered glass funnel using ethyl acetate. The hot suspension was filtered through the pad of Celite® 545. The Celite® 545 was washed with ethyl acetate until no compound was seen on TLC of the washings.
[0099] The filtrate (pale-yellow) was reduced to volume of 35-40 L by evaporation in vacuo at 50-55° C. for direct use in next step.
Example 3
Conversion of Treprostinil to Treprostinil Diethanolamine Salt (1:1)
[0100]
[0000]
Name
MW
Amount
Mol
Eq
Treprostinil
390.52
1464 g*
3.75
1.0
Diethanolamine
105.14
435 g
4.14
1.1
Ethanol
—
5.1 L
—
—
Ethyl acetate
—
35 L**
—
—
Treprostinil Diethanolamine
—
12 g
—
—
Salt (seed)
*Note: This weight is based on 100% yield from benzindene triol. It is not isolated yield. The treprostinil was carried from previous step in ethyl acetate solution and used as such for this step.
**Note: The total volume of ethyl acetate should be in range of 35-36 L (it should be 7 times the volume of ethanol used). Approximately 35 L of ethyl acetate was carried over from previous step and additional 1.0 L of ethyl acetate was used for rinsing the flask.
[0101] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of treprostinil in ethyl acetate (35-40 L from the previous step), anhydrous ethanol (5.1 L) and diethanolamine (435 g). While stirring, the reaction mixture was heated to 60-75° C., for 0.5-1.0 h to obtain a clear solution. The clear solution was cooled to 55±5° C. At this temperature, the seed of polymorph B of treprostinil diethanolamine salt (˜12 g) was added to the clear solution. The suspension of polymorph B was stirred at this temperature for 1 h. The suspension was cooled to 20±2° C. overnight (over a period of 16-24 h). The treprostinil diethanolamine salt was collected by filtration using Aurora filter equipped with filter cloth, and the solid was washed with ethyl acetate (2×8 L). The treprostinil diethanolamine salt was transferred to a HDPE/glass container for air-drying in hood, followed by drying in a vacuum oven at 50±5° C. under high vacuum.
[0102] At this stage, if melting point of the treprostinil diethanolamine salt is more than 104° C., it was considered polymorph B. There is no need of recrystallization. If it is less than 104° C., it is recrystallized in EtOH-EtOAc to increase the melting point.
[0103] Data on Treprostinil Diethanolamine Salt (1:1)
[0000]
Wt. of
Wt. of Treprostinil
Batch
Benzindene Triol
Diethanolamine Salt
Yield
Melting point
No.
(g)
(1:1) (g)
(%)
(° C.)
1
1250
1640
88.00
104.3-106.3
2
1250
1528
82.00*
105.5-107.2
3
1250
1499
80.42**
104.7-106.6
4
1236
1572
85.34
105-108
*Note: In this batch, approximately 1200 mL of ethyl acetate solution of treprostinil before carbon treatment was removed for R&D carbon treatment experiments.
**Note: This batch was recrystallized, for this reason yield was lower.
Example 4
Heptane Slurry of Treprostinil Diethanolamine Salt (1:1)
[0104]
[0000]
Name
Batch No.
Amount
Ratio
Treprostinil
1
3168 g
1
Diethanolamine Salt
Heptane
—
37.5 L
12
Treprostinil
2
3071 g
1
Diethanolamine Salt
Heptane
—
36.0 L
12
[0105] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with slurry of treprostinil diethanolamine salt in heptane (35-40 L). The suspension was heated to 70-80° C. for 16-24 h. The suspension was cooled to 22±2° C. over a period of 1-2 h. The salt was collected by filtration using Aurora filter. The cake was washed with heptane (15-30 L) and the material was dried in Aurora filter for 1 h. The salt was transferred to trays for air-drying overnight in hood until a constant weight of treprostinil diethanolamine salt was obtained. The material was dried in oven under high vacuum for 2-4 h at 50-55° C.
[0106] Analytical data on and Treprostinil Diethanolamine Salt (1:1)
[0000]
Test
Batch 1
Batch 2
IR
Conforms
Conforms
Residue on Ignition (ROI)
<0.1% w/w
<0.1% w/w
Water content
0.1% w/w
0.0% w/w
Melting point
105.0-106.5° C.
104.5-105.5° C.
Specific rotation [α] 25 589
+34.6°
+35°
Organic volatile impurities
Ethanol
Not detected
Not detected
Ethyl acetate
Not detected
<0.05% w/w
Heptane
<0.05% w/w
<0.05% w/w
HPLC (Assay)
100.4%
99.8%
Diethanolamine
Positive
Positive
Example 5
Conversion of Treprostinil Diethanolamine Salt (1:1) to Treprostinil
[0107]
[0108] A 250-mL, round-bottom flask equipped with magnetic stirrer was charged with treprostinil diethanolamine salt (4 g) and water (40 mL). The mixture was stirred to obtain a clear solution. To the clear solution, ethyl acetate (100 mL) was added. While stirring, 3M HCl (3.2 mL) was added slowly until pH ˜1 was attained. The mixture was stirred for 10 minutes and organic layer was separated. The aqueous layer was extracted with ethyl acetate (2×100 mL). The combined organic layers was washed with water (2×100 mL), brine (1×50 mL) and dried over anhydrous Na 2 SO 4 . The ethyl acetate solution of treprostinil was filtered and the filtrate was concentrated under vacuum at 50° C. to give off-white solid. The crude treprostinil was recrystallized from 50% ethanol in water (70 mL). The pure treprostinil was collected in a Buchner funnel by filtration and cake was washed with cold 20% ethanolic solution in water. The cake of treprostinil was air-dried overnight and further dried in a vacuum oven at 50° C. under high vacuum to afford 2.9 g of treprostinil (Yield 91.4%, purity (HPLC, AUC, 99.8%).
[0109] Analytical Data on Treprostinil from Treprostinil Diethanolamine Salt (1:1) to Treprostinil
[0000]
Batch No.
Yield
Purity (HPLC)
1
91.0%
99.8% (AUC)
2
92.0%
99.9% (AUC)
3
93.1%
99.7% (AUC)
4
93.3%
99.7% (AUC)
5
99.0%
99.8% (AUC)
6
94.6%
99.8% (AUC)
Example 6
Comparison of the Former Process and a Working Example of the Process According to the Present Invention
[0110]
[0000]
Working example of the
Process according to the
Step
Former Process
present invention
No.
Steps
(Batch size: 500 g)
(Batch size: 5 kg)
Nitrile
1
Triol weight
500 g
5,000 g
2
Acetone
20 L (1:40 wt/wt)
75 L (1:15 wt/wt)
3
Potassium
1,300 g (6.4 eq)
5,200 g (2.5 eq)
carbonate
4
Chloroacetonitrile
470 g (4.2 eq)
2,270 g (2 eq)
5
Tetrabutylammonium
42 g (0.08 eq)
145 g (0.03 eq)
bromide
6
Reactor size
72-Liter
50-gallon
7
Reflux time
8 hours
No heating,
Room temperature (r.t.) 45 h
8
Hexanes addition
Yes (10 L)
No
before filtration
9
Filter
Celite
Celite
10
Washing
Ethyl acetate (10 L)
Acetone (50 L)
11
Evaporation
Yes
Yes
12
Purification
Silica gel column
No column
Dichloromethane: 0.5 L
Ethyl acetate: 45 L
Hexane: 60 L
13
Evaporation after
Yes
No
column
14
Yield of nitrite
109-112%
Not checked
Treprostinil (intermediate)
15
Methanol
7.6 L (50-L reactor)
50 L (50-gal reactor)
16
Potassium
650 g (8 eq)
3,375g (4 eq)
hydroxide
17
Water
2.2 L
17 L
18
% of KOH
30%
20%
19
Reflux time
3-3.5 h
4-5 h
20
Acid used
2.6 L (3M)
12 L (3M)
21
Removal of
3 × 3 L Ethyl acetate
2 × 20 L Ethyl acetate
impurities
22
Acidification
0.7 L
6.5 L
23
Ethyl acetate
5 × 17 L = 35 L
90 + 45 + 45 = 180 L
extraction
24
Water washing
2 × 8 L
3 × 40 L
25
Sodium bicarbonate
Not done
120 g in 30 L water + 15 L
washing
brine
26
Brine washing
Not done
1 × 40 L
27
Sodium sulfate
1 kg
Not done
28
Sodium sulfate
Before charcoal, 6 L
N/A
filtration
ethyl acetate
29
Charcoal
170 g, reflux for 1.5 h,
Pass hot solution (75° C.)
filter over Celite, 11 L
through charcoal cartridge
ethyl acetate
and clean filter, 70 L ethyl
acetate
30
Evaporation
Yes, to get solid
Yes, adjust to 150 L
intermediate treprostinil
solution
Treprostinil Diethanolamine Salt
31
Salt formation
Not done
1,744 g diethanolamine,
20 L ethanol at 60-75° C.
32
Cooling
N/A
To 20° C. over weekend;
add 40 L ethyl acetate;
cooled to 10° C.
33
Filtration
N/A
Wash with 70 L ethyl
acetate
34
Drying
N/A
Air-dried to constant wt.,
2 days
Treprostinil (from 1.5 kg Treprostinil diethanolamine salt)
35
Hydrolysis
N/A
15 L water + 25 L ethyl
acetate + HCl
36
Extraction
N/A
2 × 10 L ethyl acetate
37
Water wash
N/A
3 × 10 L
38
Brine wash
N/A
1 × 10 L
39
Sodium sulfate
N/A
1 kg, stir
40
Filter
N/A
Wash with 6 L ethyl
acetate
41
Evaporation
N/A
To get solid, intermediate
Treprostinil
42
Crude drying on tray
1 or 3 days
Same
43
Ethanol & water for
5.1 L + 5.1 L
10.2 L + 10.2 L (same %)
cryst.
44
Crystallization in
20-L rotavap flask
50-L jacketed reactor
45
Temperature of
2 h r.t., fridge −0° C. 24 h
50° C. to 0° C. ramp, 0° C.
crystallization
overnight
46
Filtration
Buchner funnel
Aurora filter
47
Washing
20% (10 L) cooled
20% (20 L) cooled
ethanol-water
ethanol-water
48
Drying before oven
Buchner funnel (20 h)
Aurora filter (2.5 h)
Tray (no)
Tray (4 days)
49
Oven drying
15 hours, 55° C.
6-15 hours, 55° C.
50
Vacuum
<−0.095 mPA
<5 Torr
51
UT-15 yield weight
~535 g
~1,100 g
52
% yield from triol)
~91%
~89%
53
Purity
~99.0%
99.9%
[0111] The quality of treprostinil produced according to this invention is excellent. The purification of benzindene nitrile by column chromatography is eliminated. The impurities carried over from intermediate steps (i.e. alkylation of triol and hydrolysis of benzindene nitrile) are removed during the carbon treatment and the salt formation step. Additional advantages of this process are: (a) crude treprostinil salts can be stored as raw material at ambient temperature and can be converted to treprostinil by simple acidification with diluted hydrochloric acid, and (b) the treprostinil salts can be synthesized from the solution of treprostinil without isolation. This process provides better quality of final product as well as saves significant amount of solvents and manpower in purification of intermediates.
[0112] Although the foregoing refers to particular preferred embodiments, it will be understood that the present invention is not so limited. It will occur to those of ordinary skill in the art that various modifications may be made to the disclosed embodiments and that such modifications are intended to be within the scope of the present invention.
[0113] All of the publications, patent applications and patents cited in this specification are incorporated herein by reference in their entirety. | This present invention relates to an improved process to prepare prostacyclin derivatives. One embodiment provides for an improved process to convert benzindene triol to treprostinil via salts of treprostinil and to purify treprostinil. | 2 |
PRIORITY CLAIM
[0001] This application claims benefit of and hereby incorporates by reference provisional patent application Ser. No. 61/238,091, entitled “Enclosed Smoking Device,” filed on Aug. 28, 2009, by inventor Kelly J. Adamic; provisional patent application Ser. No. 61/242,229, entitled “Enclosed Smoking Device with Timed Ignition Button,” filed on Sep. 14, 2009, by inventor Kelly J. Adamic; and provisional patent application Ser. No. 61/327,064, entitled “Smoke and Odor Elimination Filter and Devices,” filed on Apr. 22, 2010, by inventor Kelly J. Adamic.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
TECHNICAL FIELD
[0003] This invention relates generally to smoking devices, and more particularly relates to smoke and odor elimination filters, devices and methods.
BACKGROUND
[0004] Smoking is a practice in which a combustible substance, e.g., tobacco, cannabis or herbs, is burned and the resulting smoke inhaled. Combustion of the substance causes the release of active drugs such as nicotine or THC and makes them available for absorption through the lungs. The most common way of smoking today is through cigarettes, primarily industrially manufactured but also hand-rolled using rolling paper. Other smoking tools includes traditional pipes, cigars, hookahs and bongs.
[0005] People smoke for recreation, as a part of rituals, in search of a spiritual enlightenment, and for medical purposes. The history of smoking can be dated to as early as 5000 BC, and has been recorded in many different cultures around the world. Early smoking evolved in association with religious ceremonies, as offerings to deities, in cleansing rituals, or as a process of divination. The practice of smoking has become commonplace.
[0006] It will be appreciated that, while cannabis for recreational use is illegal in many parts of the world, its use as a medicine is legal in a number of territories, including Canada, Austria, Germany, the Netherlands, Spain, Israel, Italy, Finland, and Portugal. In the United States, permission for medical cannabis varies from state to state, several having enacted laws to allow regulated cannabis consumption, possession, cultivation, and distribution for medicinal use.
[0007] When non-smokers are exposed to secondhand smoke, it is commonly referred to as passive smoking. Non-smokers who breathe in secondhand smoke take in the nicotine, THC and/or other chemicals just like smokers do. Passive smoking has played a central role in the debate over the harms and regulation of tobacco products. Since the early 1970s, the tobacco industry has been concerned about passive smoking as a serious threat to its business interests. Passive smoking was perceived as motivation for stricter regulation of tobacco products as well as for smoking bans in workplaces and indoor public establishments, such as restaurants, bars and night clubs.
[0008] Smoking releases odors that get into hair, clothing, and other surfaces, even after the smoke is no longer visible. Some researchers call this remnant odor “thirdhand” smoke. Essentially, the particles caused by smoking settle on surfaces and can be measured long after a person has finished smoking.
[0009] What is desired is a mechanism for reducing or eliminating secondhand and thirdhand smoke.
SUMMARY
[0010] In accordance with some embodiments, the present invention provides a pipe, comprising a combustion bowl with bowl vents; an inhalation path for drawing smoke from the combustion bowl through the bowl vents during inhalation; an exhalation filter; and an exhalation path for forcing exhaled smoke through the exhalation filter during exhalation.
[0011] The pipe may further comprise a mouthpiece on both the inhalation path and the exhalation path. The inhalation path may include a one-way inhalation valve between the combustion bowl and the mouthpiece. The pipe may further comprise a lid over the combustion bowl, the lid creating a substantially airtight inhalation seal with the combustion bowl. The lid may include a one-way inhalation valve. The pipe may further comprise exhalation vents, wherein the exhalation path includes a one-way exhalation valve between the mouthpiece and the exhalation vents. The one-way exhalation valve may be part of the exhalation filter. The exhalation filter may include an exhalation filter cartridge. The pipe may further comprise an internal lighter for providing a flame to the combustion bowl. The pipe may further comprise a timed ignition switch for controlling the length of time that a flame is delivered to the combustion bowl. The exhalation filter may include a housing, a HEPA filter, and a foam core. The foam core may include a central bore extending the length of the foam core, and the foam core includes odor absorbing chemicals for removing the odor from the exhaled smoke.
[0012] In accordance with some embodiments, the present invention provides a method, comprising burning a combustible substance in a combustion bowl having bowl vents, the burning combustible substance creating smoke; channeling at least portions of the smoke from the combustion bowl through the bowl vents to a smoker; receiving exhaled smoke from the smoker; channeling the exhaled smoke to an exhalation filter; and filtering the exhaled smoke by the exhalation filter.
[0013] The smoke from the combustion bowl may be channeled to the smoker via a mouthpiece and the exhaled smoke may be received through the same mouthpiece. The method may further comprise preventing the exhaled smoke from being delivered to the combustion bowl. The method may further comprise preventing the smoke from the combustion bowl from including air from the exhalation filter. The method may further comprise controlling the length of time that a flame is delivered to the combustible substance in the combustion bowl. The exhalation filter may include a housing, a HEPA filter, and a foam core. The foam core may include a central bore extending the length of the foam core, and the foam core may include odor absorbing chemicals for removing the odor from the exhaled smoke.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 a - 1 e illustrate a smoke and odor elimination smoking pipe, in accordance with an embodiment.
[0015] FIG. 2 is an exploded view of the pipe of FIG. 1 , in accordance with an embodiment.
[0016] FIG. 3 is an exploded view of the flip-top lid assembly of the pipe of FIG. 1 , in accordance with an embodiment.
[0017] FIG. 4 is an exploded view of the flip-top lid assembly of FIG. 2 positioned for connection to the bowl housing of FIG. 1 , in accordance with an embodiment.
[0018] FIGS. 5 a - 5 f illustrate the internal details of the pipe of FIG. 1 , in accordance with an embodiment.
[0019] FIG. 6 is a sectional view of a smoke and odor elimination smoking pipe, in accordance with an embodiment.
[0020] FIG. 7 illustrates an exploded view of an exhalation pipe, in accordance with an embodiment.
[0021] FIGS. 8 a - 8 d illustrate details of the exhalation pipe of FIG. 7 , in accordance with an embodiment.
[0022] FIGS. 9 a - 9 e illustrate a smoke and odor elimination smoking pipe, in accordance with an embodiment.
[0023] FIG. 10 a illustrates an exploded view of the pipe of FIGS. 9 a - 9 e , in accordance with an embodiment.
[0024] FIG. 10 b illustrates an exploded view of the pipe of FIGS. 9 a - 9 e , in accordance with an embodiment.
[0025] FIGS. 11 a - 11 c illustrate details of the pipe of FIGS. 9 a - 9 e , in accordance with an embodiment.
[0026] FIGS. 12 a - 12 c illustrate the pipe of FIGS. 9 a - 9 e , in accordance with an embodiment.
[0027] FIG. 13 is a sectional side view of a smoke and odor elimination smoking pipe, in accordance with an embodiment.
[0028] FIG. 14 is a sectional side view of a smoke and odor elimination smoking pipe, in accordance with an embodiment.
[0029] FIG. 15 is a section side view of the ignition button assembly of FIG. 14 in accordance with an embodiment.
[0030] FIGS. 16 a - 16 e illustrate the exhalation filter cartridge, in accordance with an embodiment.
[0031] FIGS. 17 a and b illustrate details of the exhalation filter cartridge of FIGS. 16 a - 16 e , in accordance with an embodiment.
[0032] FIG. 18 is an exploded view of the exhalation filter cartridge of FIGS. 16 a - 16 e , in accordance with an embodiment.
[0033] FIG. 19 is an exploded view of the exhalation filter cartridge of FIGS. 16 a - 16 e , in accordance with an embodiment.
[0034] FIGS. 20 a - 20 d illustrate an exhalation filter cartridge with a retaining clip, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0035] The following description is provided to enable any person skilled in the art to make and use the invention. Various modifications to the embodiments are possible, and the generic principles defined herein may be applied to these and other embodiments and applications without departing from the spirit and scope of the invention. Thus, the invention is not intended to be limited to the embodiments and applications shown, but is to be accorded the widest scope consistent with the principles, features and teachings disclosed herein.
[0036] FIGS. 1 a - 1 e illustrate a smoke and odor elimination pipe 100 , in accordance with an embodiment of the present invention. FIG. 1 a is a perspective view of the pipe 100 . FIG. 1 b is a side view of the pipe 100 . FIG. 1 c is a top view of the pipe 100 . FIG. 1 d is a bottom view of the pipe 100 . FIG. 1 e is a front view of the pipe 100 .
[0037] As shown in FIGS. 1 a - 1 e , the pipe 100 has six sides, namely, a top side 151 , a bottom side 152 , a front side 153 , a rear side 154 , a left side 155 , and a right side 156 . The pipe 100 includes a mouthpiece 105 and one-way exhalation vents 115 on the front side 153 , and a flip-top lid 110 with one-way inhalation vents 120 on the top side 151 .
[0038] In use, the smoker opens the lid 110 , exposing a combustion bowl (not shown) with combustible substance therein. The smoker applies a flame over the combustible substance, e.g., using a butane lighter, and inhales through the mouthpiece 105 . Airflow causes the combustible substance to burn and smoke to pass through an inhalation path in the pipe 100 via an inhalation filter (not shown) and out the mouthpiece 105 to the smoker. The smoker closes the lid 110 , which effectively prevents air from flowing out the opening exposed when the lid 110 is open. Air can still be drawn through the one-way inhalation vents 120 . The smoker then exhales through the same mouthpiece 105 . The smoke passes through an exhalation path in the pipe 100 through an exhalation filter (not shown) and out the exhalation vents 115 . The exhalation filter scrubs the smoke and odor particles.
[0039] In one embodiment, the pipe 100 is about 4 inches long (front to rear), 1.5 inches tall (top to bottom), and ⅞ inch wide (left to right). Components of the pipe 100 may be made of a metal such as aluminum or of plastic.
[0040] FIG. 2 is an exploded view of the pipe 100 , in accordance with an embodiment of the present invention.
[0041] The pipe 100 includes a body 201 with two channels, namely, a lower channel 210 and an upper channel 211 . An end cap 208 with a through-hole (not shown) is positioned on the rear end of the lower channel 210 . A bowl housing 202 , possibly made of aluminum, is positioned near the rear side of the body 201 , behind the end cap 208 . Although not shown, bowl vents may be disposed on the underside of the bowl 212 . The shape of the bowl housing 202 allows air to be drawn through the bowl vents on the underside of the bowl 212 to an intermediate chamber behind the end cap 208 and through the upper channel 211 . Although not shown, in some embodiments, an inhalation filter may be positioned in the upper channel 211 . The shape of the bowl housing 202 also allows air to pass from the upper channel to the intermediate chamber under the bowl 212 , through the end cap 208 , and through the lower channel 210 .
[0042] A fitting 205 is positioned in the front end of the body 201 . The fitting 205 includes two passageways, namely, an upper passageway 213 that interfaces with the upper channel 211 and a lower passageway 214 that interfaces with the lower channel 210 . In some embodiments, the fitting 205 is attached airtight to the body 210 , e.g., using glue. The upper passageway 213 may be configured to accept the mouthpiece 105 mounted therein, possibly with an o-ring 204 therebetween to create an airtight seal. The lower passageway 214 may be configured to accept an exhalation filter cartridge 203 into the lower channel 210 and an exhalation vent cap 206 . In some embodiments, the exhalation vent cap 206 is removable to allow replacement of the exhalation filter cartridge 203 . In some embodiments, the end cap 206 is part of or integrated with the exhalation filter cartridge 203 .
[0043] The pipe 100 includes an inhalation path and an exhalation path. As shown and described with reference to the pipe 100 , the inhalation path and exhalation path of pipe 100 overlap. To ensure that air is not drawn from the exhalation filter cartridge 203 during inhalation and that air is not forced through the combustion bowl 212 during exhalation, one or more one-way inhalation valves and one or more one-way exhalation valves may be employed. In some embodiments, the one-way inhalation valve may be attached to the flip top lid 110 . In some embodiments, the one-way inhalation valve may be a flap (similar to the flap 303 of FIG. 3 ) positioned on the under side of the flip-top lid 110 . Therefore, during exhalation, the inhalation flap prevents air from exiting the flip-top lid 110 , and forces the air through the lower channel. In some embodiments, a one-way exhalation valve may be disposed in or on the exhalation filter cartridge 203 , in the body 201 , on the end cap 208 , or in the exhalation vent cap 206 . In some embodiments, the one-way exhalation valve may be a flap (similar to the flap 303 of FIG. 3 ) positioned on the front side of the end cap 208 . Thus, during inhalation, the flap prevents air from being drawn from the lower channel 210 , and allows air to flow through the lower channel.
[0044] FIG. 3 is an exploded view of a flip-top lid assembly 300 , in accordance with some embodiments. The flip-top lid assembly 300 includes the flip-top lid 110 with inhalation vents 120 therethrough, a rear wall 312 extending downward from the backside of the lid 110 , a pivot bore 310 through the rear wall 312 from the left to the right, and a finger lever 311 that when positioned on the body 201 extends past the rear side 154 to cause rotation of the flip-top lid about the pivot bore 310 when pressed upon. A first dowel 308 is inserted into the pivot bore 310 and lee torsion springs 307 are attached to the first dowel 308 . The first dowel 308 may include a dowel bore 315 therethrough.
[0045] As shown, a one-way inhalation flap 303 may be attached to the lid 110 to prevent airflow out of the inhalation vents 120 . A lid gasket 302 may be positioned on the underside of the lid 110 , and held in place by a combustion bowl plate 305 . The combustion bowl plate 305 may be secured to the lid 110 using screws 304 . It will be appreciated that the combustion bowl plate 305 may be made of metal to protect the gasket 302 and the one-way inhalation flap 303 from damage by the burning combustible substance in the bowl 212 .
[0046] FIG. 4 is an exploded view of the flip-top lid assembly 300 positioned for connection to the bowl housing 202 . As shown, a second dowel 403 may be positioned through holes 402 in the bowl housing 202 and through the dowel bore 315 of the first dowel 308 . It will be further appreciated that the lee torsion springs 307 may be used to bias the flip-top lid 110 in a closed and to press the lid gasket 302 in an airtight position on the bowl housing 202 . Pressing on the finger lever 311 causes a rotational force to counter the bias of the springs 307 , thus opening the flip-top lid assembly 300 to expose the bowl 212 .
[0047] FIGS. 5 a - 5 f illustrate the internal details of the pipe 100 , in accordance with an embodiment of the present invention.
[0048] FIG. 5 a illustrates a front view of the pipe 100 , and identifies plane A-A half way between the left and right sides of the front face.
[0049] FIG. 5 b illustrates a sectional view of the pipe 100 at plane A-A. When the flip-top lid 110 is open or closed, inhalation draws air from the mouthpiece 105 , which draws air from the upper channel 211 , which draws air from an intermediate path 503 , which draws air from a intermediate chamber 505 under the bowl 212 . A one-way exhalation flap 507 prevents air from being drawn from the lower channel 210 and the exhalation filter cartridge 203 . Instead, air is drawn through bowl vents 520 on the underside of the bowl 212 , which draws smoke from the burning combustible substance in the bowl 212 . This may be referred to as the “inhalation path,” in this embodiment. During exhalation, air is forced into the mouthpiece 105 , which forces air into the upper chamber 211 , which forces air through the intermediate path 503 to the intermediate chamber 505 . The one-way inhalation flap 303 in the flip-top lid assembly 300 (see FIG. 3 ) prevents air from being forced through combustion bowl 202 . Instead, the one-way exhalation flap 507 in the lower channel 210 opens, allowing the air to pass into the lower channel 210 , though the exhalation filter cartridge 203 , and out the exhalation vents 115 . In some embodiments, the exhalation flap 507 (or some other one-way exhalation valve) may be positioned in this and/or other locations, such as in the exhalation filter cartridge 203 or near the exhalation vents 115 . This may be referred to as the “exhalation path,” in this embodiment.
[0050] FIG. 5 c illustrates a sectional view of the rear portion of the pipe 100 through the bowl 212 . As shown, bowl housing 202 includes bowl vents 520 between the bowl 212 and the chamber 505 .
[0051] FIG. 5 d illustrates a side view of the pipe 100 , in accordance with an embodiment of the present invention. FIG. 5 d defines plane B-B as a section through the upper channel 211 and defines plane C-C as a section through the lower channel 210 .
[0052] FIG. 5 e illustrates sectional view of plane B-B of the pipe 100 . As shown, the bottom of the bowl 212 includes bowl vents 520 .
[0053] FIG. 5 f illustrates sectional view at plane C-C of the pipe 100 . As shown, in an embodiment, the lower channel 210 may include ridges that cooperate with ridges on the exhalation filter cartridge 203 .
[0054] FIG. 6 is a sectional view of an example pipe 500 , in accordance with an embodiment of the invention. The pipe 500 includes an upper channel 635 , a lower channel 655 , and an intermediate channel 640 . An exhalation filter 650 is positioned in the lower channel 655 . A one-way exhalation valve 645 is positioned in the intermediate channel 640 . A one-way inhalation valve 630 is positioned in the upper channel 635 . A mouthpiece is positioned at the front side of the upper channel 635 of the pipe 500 . A flip-top lid 605 is positioned at the rear side of the upper channel 635 of the pipe 500 . A combustion bowl 615 is positioned under the flip-top lid 605 . An inhalation filter 620 is positioned between the bowl 615 and the mouthpiece 625 in the upper channel 635 . Exhalation vents 655 are positioned in the front side of the lower channel 655 of the pipe 500 .
[0055] Accordingly, during inhalation, air is drawn from the mouthpiece 625 . The one-way inhalation valve 630 allows air to pass through the upper channel 635 , through the inhalation filter 620 , and from the combustion bowl 615 . The exhalation valve 645 prevents air from being drawn from the lower channel 655 . During exhalation, air is forced into the mouthpiece 625 , which forces air through the intermediate channel 640 via the one-way exhalation valve 645 , to the lower channel 655 , through the exhalation filter 650 and out the exhalation vents 655 . The one-way inhalation valve 630 prevents are being exhaled through the inhalation filter 620 or the combustion bowl 615 .
[0056] FIG. 7 illustrates an exploded view of an exhalation pipe 700 , in accordance with an embodiment of the present invention.
[0057] As shown, the exhalation pipe 700 includes an elliptical body 705 with a filter channel 725 therethrough, threading (not shown) on the rear internal side of the elliptical body 705 , and a passageway (not shown) on the front side. A mouthpiece 710 is attached onto the front side of the elliptical body (possibly with glue). An exhalation filter cartridge 203 is inserted into the filter channel 725 . An end cap 715 includes exhalation vents 720 and threading 730 that cooperates with the threading in the body 705 .
[0058] In use, the smoker inhales smoke from a cigarette, pipe, bong, cigar or other smoking apparatus. The smoker then exhales through the mouthpiece 710 . The smoke travels through the mouthpiece 710 , through the passageway, into the channel 725 , through the exhalation filter cartridge 203 , and out the exhalation vents 720 . The filter 203 scrubs the smoke and odor particles.
[0059] In some embodiments, the body 705 may be made of extruded aluminum, plastic, ferrous metals, precious metals, etc. The mouthpiece 710 may be machined stainless steel, plastic, ferrous metals, precious metals, etc. The end cap 715 may be machined stainless steel, plastic, ferrous metals, precious metals, etc.
[0060] FIGS. 8 a - 8 d illustrate an exhalation pipe 700 .
[0061] FIG. 8 a illustrates a side view of the exhalation pipe 700 . As shown, the pipe 700 may be about 4 inches in length, e.g., 3.93 inches. FIG. 8 a defines plane A-A.
[0062] FIG. 8 b illustrates a sectional view of exhalation pipe 700 at plane A-A. As shown, the pipe 700 includes a mouthpiece press fit to the body 705 . The end cap 715 is screwed onto the body 705 via threading 730 .
[0063] FIG. 8 c illustrates a front view of the pipe exhalation 700 . As shown, in some embodiments, the pipe 700 is about 1.3 inches across the longitudinal axis of the elliptical body 705 and about 0.95 inches across the latitudinal axis of the elliptical body 705 . The diameter of the circular end cap 715 may be about 1.3 inches, allowing portions of it to extend beyond the body 705 for easy rotational manipulation by the user.
[0064] FIG. 8 d illustrates a rear view of the exhalation pipe 700 . As shown, the end cap 715 includes exhalation vents 720 .
[0065] FIGS. 9 a - 9 e illustrate a pipe 900 , in accordance with an embodiment of the present invention. As will be described in more detail below, the pipe 900 includes a combustion section, a filter cartridge section, as well as an internal lighter section.
[0066] In some embodiments, the pipe 900 is about 4 inches tall (top to bottom), 3 inches long (front to rear), and ⅞ inches wide (left to right). As shown, the pipe 900 includes a body 910 . A mouthpiece 905 is rotatably attached to the front side of the body 910 . A cap 915 is slidably mounted on the top of the body 905 . Sliding the cap 915 forward exposes the combustion bowl (not shown) therein. Sliding the cap 915 towards the rear will allow the mouthpiece 905 to flip open. In some embodiments, sliding the cap forward after opening the mouthpiece secures the mouthpiece in its open position. An ignition switch 920 ignites the internal lighter, which causes combustible substance in the combustion bowl to ignite. The smoker can inhale the smoke through the mouthpiece 905 via an inhalation path and exhale the smoke through the same mouthpiece via an exhalation path to filter the smoke and odor.
[0067] FIG. 10 a is an exploded view of the pipe 900 , in accordance with some embodiments of the present invention. The pipe 900 includes a body 1001 having three channels, namely, a front channel 1020 , a center channel 1022 , and a rear channel 1024 . An exhalation filter cartridge 203 is positioned in the center channel 1022 . A lighter 1004 is positioned in the rear channel 1024 . A bottom cap 1012 with exhalation vents 1036 may be slidably mounted on the bottom of the body 1001 .
[0068] The front channel 1020 may be used for storage of combustible substance. This storage may be locked in place using spring-loaded ball bearings that drop into receiving indents on the compartment. Some embodiments may use a swing out storage hinged along the vertical edge of the compartment and the device. Other embodiments may use a fold back compartment that is hinged at the bottom of the compartment and device.
[0069] A fitting 1005 may be inserted into the top side of the body 1001 , above the three channels. The fitting 1005 may include a mouthpiece attachment portion 1026 in the front of the fitting 1005 . A mouthpiece 905 and mouthpiece seal 1008 may be attached to the mouthpiece attachment portion 1026 . In some embodiments, the mouthpiece seal 1008 includes five flat faces and one arcuate face. The arcuate face may cooperate with an arcuate section of the mouthpiece 905 to enable the mouthpiece 905 to rotate from a position flush with the front face of the body 1001 to a position normal to the front face of the body 1001 . A pin (not shown) may be slidably inserted through holes 1032 in the fitting 1002 and through a pivot bore 1030 in the mouthpiece 905 . When the mouthpiece 905 is inserted into the body 1001 , the dowel may be held in place by the side walls of the body 1001 .
[0070] The fitting 1002 may also include notches 1034 , which abut the top portion of the walls dividing the body 1001 into its three channels. The notches 1034 may provide a better airtight seal between the fitting 1002 and the body 1001 . The fitting 1002 also includes a combustion bowl 1028 , possibly made of aluminum, with flame access holes (not shown) on the bottom side of the bowl 1028 . The fitting 1002 may be attached to the body 1001 , possibly using glue, to provide an airtight seal.
[0071] A top lid 915 may be slidably attached to the fitting 1002 or the body 1001 . A spring pin 1005 , washer 1006 and set screw 1007 may cooperate with the top lid 915 to retain the lid 915 in open or closed position. Some embodiments of the device may use a porcelain lighter compartment top dome insert and a combustion chamber insert to help contain heat generated during combustion.
[0072] An external ignition switch 920 may be slidably mounted through the body 1001 to engage an internal ignition switch on the lighter 1004 . Upon activation, the lighter will ignite causing a flame through the flame access holes under the combustion bowl 1028 , causing the combustible substance to burn.
[0073] Like the pipe 100 , the pipe 900 will include an inhalation path from the combustion bowl through an inhalation filter to the mouthpiece 905 and an exhalation path from the mouthpiece 905 through the exhalation filter cartridge 203 and out the exhalation vents 1036 .
[0074] FIG. 10 b is an exploded view of a pipe 1050 , in accordance with an embodiment of the present invention. The pipe 1050 is similar to the pipe 900 described above with reference to FIGS. 9 and 10 a . In this case, pipe 1050 includes a body 1053 with no channels therein. A storage chamber 1060 , exhalation filter cartridge 203 , and lighter assembly 1004 are disposed into the body 1053 tightly against the inside walls of the body 1053 and tightly against each other, thus dividing the body into three sections, similar to the pipe 900 . A fitting 1055 similar to fitting 1002 is inserted above the three sections. Like the fitting 1002 , the fitting 1055 creates the channels for separate inhalation and exhalation paths. The fitting 1055 supports mouthpiece 905 , using dowels 1062 and mouthpiece seal 1008 . A bowl lid 1054 , gasket 1056 , spring 1056 and pin 1058 cooperate to form a flip-top lid assembly over the bowl 1028 in the fitting 1054 . Lighter cap assembly 1068 is positioned at the bottom of the lighter assembly 1004 to enable airflow, possibly one way, to the lighter assembly 1004 as needed through a lighter vent 1070 in the bottom cap 1072 . A top cover wear-strip 1051 may be attached to the top cap 915 to enable the top cap 915 to slide comfortably and not loosely across the top of the body 1053 or fitting 1053 . An ignition switch assembly including ignition switch 920 , ignition switch wear surface 1064 and slider block 1066 , enables the user to ignite the lighter, which burns the combustible substance.
[0075] FIG. 11 a is a side view of the pipe 900 , in accordance with an embodiment. FIG. 11 a defines plane A-A through the center of the rear channel 1024 and plane B-B through the center of the center channel 1022 .
[0076] FIG. 11 b is a sectional view of the pipe 900 at plane A-A. As shown, the lighter 1004 is positioned within the rear channel 1024 . Upon ignition, the lighter 1004 causes a flame 1138 to pass through flame access holes 1180 in the combustion bowl 1028 .
[0077] FIG. 11 c is a sectional view of the pipe 900 at plane B-B. As shown, the exhalation filter cartridge 203 is inserted into the center channel 1022 above the exhalation vents 1036 . The exhalation filter cartridge 203 also cooperates with an intermediate channel 1140 from which it receives air exhaled from the smoker.
[0078] FIGS. 12 a - 12 c illustrate the pipe 900 , in accordance with some embodiments. FIG. 12 a is a front view of the pipe 900 and defines a plane C-C through the center of the front face and a plane H-H at about the ¾ position of the front face from the left side.
[0079] FIG. 12 b is a sectional view of the pipe 900 at plane C-C. As shown, a storage chamber 1020 is positioned in the front channel 1022 , the exhalation filter cartridge 203 is positioned in the center channel 1022 , and the lighter 1004 is positioned in the rear channel 1024 under the combustion bowl 1028 . A one-way inhalation valve 1205 is positioned between the combustion bowl 1028 to enable smoke to transfer from the combustion bowl 1208 through the intermediate channel 1210 to the mouthpiece 915 . A one-way exhalation valve 1215 may be positioned between the intermediate channel 1210 and the center channel 1022 to enable exhaled smoke to transfer from mouthpiece 915 through the intermediate channel 1210 to the center channel 1022 and exhalation filter cartridge 203 and out the exhalation vents 1036 . Alternatively or additionally, a one-way exhalation valve 1215 may be positioned inside the exhalation filter cartridge 203 as described below.
[0080] FIG. 12 c is a sectional view of the pipe 900 at plane H-H. As shown, the pin 1005 is positioned to lock the top lid 915 .
[0081] FIG. 13 is a sectional side view of a pipe 1300 , in accordance with an embodiment of the present invention. As shown, the pipe 1300 includes a mouthpiece 1302 in a pipe body 1301 . The mouthpiece 1302 is operatively coupled to an inhalation filter 1304 , which is operatively coupled via a one-way inhalation valve 1308 to a combustion bowl 1306 . A flip-top lid 1310 is positioned over the combustion bowl 1306 . The mouthpiece 1302 is also operatively coupled to an exhalation filter channel 1318 with exhalation filter media therein. An outlet cap 1320 with an integral one-way exhalation valve is positioned at the bottom end of the exhalation filter channel 1318 . A lighter 1316 is positioned in a channel below the combustion bowl 1306 . The lighter 1316 may receive air through a lighter air vent 1332 (possibly with a check valve). An ignition switch 1314 extends through the pipe body 1301 to enable user activation of the lighter 1316 . In one embodiment, during an inhalation phase, the ignition switch 1314 is depressed for one second before the person begins to inhale. During inhalation, the smoke is drawn from combustion bowl 1306 , through the one-way inhalation valve 1308 , through the inhalation filter 1304 , and through the mouthpiece 1302 . During exhalation, smoke is past through the mouthpiece 1302 , through the exhalation filter channel 1318 (and exhalation filter media), and through outlet cap 1320 . In some embodiments, the inhalation filter 1304 may be replaced by removing the mouthpiece 105 and pulling on a cartridge removal grip 1330 which protrudes into the mouthpiece 105 .
[0082] FIG. 14 is a sectional side view of a pipe 1400 , in accordance with an embodiment of the present invention. As shown, the pipe 1400 is similar to the pipe 1300 , except with a timed ignition button assembly 1405 and a lighter dust cover 1410 . The ignition button assembly 1405 ensures that the lighter is not on too long to insure that the device does not generate enough heat to be a source of injury. The lighter dust cover 1410 ensures that dust does not impede ignition of the flame.
[0083] FIG. 15 illustrates details of the ignition button assembly 1405 , in accordance with an embodiment of the present invention. The ignition button assembly 1405 includes an external ignition button 1505 , a primary oil-filled chamber 1520 , a transfer chamber 1510 , and a return spring in the primary chamber 1520 . As pressure is applied to the external ignition button 1505 , oil from the primary chamber 1520 passes through holes 1530 in the plunger 1515 into the transfer chamber 1510 , slowly releasing pressure on the ignition switch 1505 . Once the oil has traveled into the transfer chamber 1510 , the ignition switch 1505 is released and the oil is allowed to return to the primary chamber 1520 , whereby the process may be repeated.
[0084] FIGS. 16 a - 16 e illustrate the exhalation filter cartridge 203 , in accordance with an embodiment. FIG. 16 a is a perspective view of the exhalation filter cartridge 203 , which includes a front face 1602 , rear face 1604 and a central body 1606 (in this case, with a square cross section). The front face 1602 includes an opening 1608 for receiving the smoke and odor exhaled from the smoker. In this case, the opening 1608 is round with a raised lip 1610 around the perimeter of the round opening 1608 . The raised lip 1610 helps to create an airproof seal in the exhalation paths of the pipes. FIG. 16 b is a front view of the front face 1602 of exhalation filter cartridge 203 . FIG. 16 c is a rear view of the rear face 1604 of the exhalation filter cartridge 203 . FIG. 16 d is a side view of the exhalation filter cartridge 203 and defines a plane A-A and plane Z-Z. FIG. 16 e is a sectional view of the exhalation filter cartridge 203 at plane A-A. As shown, the exhalation filter cartridge 203 includes opening 1608 , filter media 1614 , an end cap 1612 , and filter exhalation vents 1616 in the end cap 1612 .
[0085] FIGS. 17 a and b illustrate details of the exhalation filter cartridge 203 , in accordance with an embodiment of the present invention. FIG. 17 a is a sectional side view of the exhalation filter cartridge 203 . As shown, the exhalation filter cartridge 203 includes an inlet cap 1620 , an outlet cap 1628 , and a filter casing 1622 therebetween. The inlet cap 1620 includes a raised lip (or “nipple”) that engages a corresponding shape inside a pipe, so that substantially all smoke exhaled passes through the filter media 1614 . A pleated HEPA filter 1624 is positioned inside the exhalation filter cartridge 203 , between the inlet cap 1620 , the outlet cap 1628 , and the filter casing 1622 . HEPA material rated at as little as a 95% rating will trap the smoke particles. A foam core 1630 is positioned between the inlet cap 1620 and the outlet cap 1628 and within the pleated HEPA filter 1624 . For example, the foam core 1630 may be manufactured from core of 60 pours-per-inch (PPI can be higher or lower) polyether polyurethane foam (or other foam).
[0086] FIG. 17 b is a sectional view of the exhalation filter cartridge 203 at plane Z-Z. As shown, the exhalation filter cartridge 203 includes a foam core 1630 , which is surrounded by the pleated HEPA filter 1624 , which is surrounded by the filter casing 1622 . The foam core 1630 includes a central bore 1632 , preferably extending the length of the foam core 1630 . The central bore 1632 allows the smoke to pass through the length of the foam core 1630 , before being forced laterally through the foam core 1630 and HEPA filter 1624 . Although not shown, a metal cap may be positioned at the bottom end of the foam core 1630 and HEPA filter 1624 to stop the downward flow of smoke and odor particles before being allowed to exit out the outlet cap 1628 , and to force the smoke and odor particles laterally towards the filter casing 1622 . The foam core 1630 may be infused with a odor capturing substance, e.g., odor absorbing materials such as Ecosorb® odor-absorbing products manufactured by OMI Industries. Citrus, mint and/or cinnamon extracts (or other extracts) can additionally or alternatively be added to the oil to provide a selection of scents.
[0087] In some embodiments, the odor absorbing materials react on a molecular level to neutralize smoke odors, preferably involving adsorption, absorption, gas solubility and reaction. For example, when Ecosorb® oil is diluted with water and broadcast via atomization, the tiny water droplets created contain a thin oil skin that creates an electrostatic charge. This charge facilitates adsorption of the odor molecules onto the droplet surface. The gas is absorbed by the droplet (solubility) and held.
[0088] FIG. 18 is an exploded view of the exhalation filter cartridge 203 , in accordance with an embodiment of the present invention. As shown, the exhalation filter cartridge 203 includes a filter casing 1622 . The inlet cap 1620 is positioned on the top side of the filter casing 1622 to form the front face 1602 . The HEPA filter 1624 is positioned inside the filter casing 1622 . An internal filter cap 1802 is positioned on the bottom side of the filter casing 1622 to support the HEPA filter 1624 and create an exhalation hole 1806 to allow exhaled air to pass therethrough. Although not shown, the foam core 1630 is positioned inside the HEPA filter 1624 . A flap 1804 , possibly made of rubber (e.g. Viton® rubber), is positioned on the bottom side of the internal filter cap 1802 to cover the exhalation hole 1806 . An outlet cap 1628 is positioned over the internal filter cap 1802 and the round flap 1804 , supporting the round flap between the internal filter cap 1802 and the outlet cap 1628 . The outlet cap 1628 includes exhalation vents 1808 outside the boundaries of the flap 1804 . Accordingly, during exhalation, air can pass through the exhalation hole 1806 , past the round flap 1804 , and out the exhalation vents 1808 . During inhalation, the flap 1804 is drawn up to cover the exhalation hole 1806 , preventing air to flow through the exhalation filter cartridge 203 .
[0089] FIG. 19 is an exploded view of the exhalation filter cartridge 203 , in accordance with an embodiment of the present invention. As shown, the exhalation filter cartridge 203 includes a filter casing 1622 . The inlet cap 1620 is positioned over the top end of the filter casing 1622 . A sponge foam seal 1904 may be positioned over the inlet cap 1620 to enable an airproof seal with the pipe body. The internal filter cap 1802 is positioned at the bottom of the filter casing 1622 . The flap is positioned over the exhalation hole 1806 . The outlet cap 1628 is positioned over the internal filter cap 1802 and the outlet cap 1628 . The foam core 1620 is positioned inside the pleated HEPA filter 1624 , which is positioned inside the filter casing 1622 . The top of the HEPA filter 1624 and foam core 1630 may be fused or glued to the inlet cap 1620 .
[0090] As stated above with reference to FIG. 18 b , the foam core 1630 includes a central bore 1632 , extending the length of the foam core 1630 . The central bore 1632 allows the smoke to pass through the entire length of the foam core 1630 , before being forced through the foam core 1630 and HEPA filter 1624 . A metal cap 1902 is positioned at the bottom end of the foam core 1630 and HEPA filter 1624 to force the smoke laterally towards the filter casing 1622 before being allowed to exit out the outlet cap 1628 . In this embodiment, the metal cap 1902 is round and the cross section of the filter casing 1622 is square. Accordingly, the metal cap 1902 forces the air to pass down the central bore 1632 , laterally through the foam core 1630 , laterally through the HEPA filter 1624 , and out the corners that extend beyond the circumference of the round metal cap 1902 .
[0091] It will be appreciated that some embodiments may use natural or synthetic fibers, ceramic, metal, chemicals, oils and/or crystals for filtering.
[0092] FIGS. 20 a - 20 d illustrate an exhalation filter cartridge 2005 with a retaining clip 2010 , in accordance with an embodiment of the present invention. FIG. 20 a is a perspective view of the exhalation filter cartridge 2005 . As shown, the exhalation filter cartridge 2005 includes a retaining clip 2010 attached to the end portion of the exhalation filter cartridge 2005 . The exhalation filter cartridge 2005 includes an end cap (similar to end cap 206 ) with exhalation vents (similar to exhalation vents 115 ) therein. FIG. 20 b is a close-up of the retaining clip 2010 . As shown, the retaining clip 2010 may be a rocker type clip, with an forward arm 2015 with a downward flanging tip 2030 , a rear arm 2020 , and a pivot base 2025 between the two arms. Depressing the rear arm 2020 will cause the pivot base 2025 to pivot and the forward arm 2015 to raise. FIG. 20 c is a perspective view of the exhalation filter cartridge 2005 positioned in the pipe 100 . FIG. 20 d is a close-up of the retaining clip 2010 when the exhalation filter cartridge 2005 is positioned in the pipe 100 . In this embodiment, the pipe 100 includes a hole 2035 configured to receive and retain the downward flanging tip 2030 of the forward arm 2015 , and a slot 2040 to receive the rear arm 2020 . The pipe 100 also includes a recessed portion 2045 to enable a user to apply downward pressure on the rear arm 2020 , when the exhalation filter cartridge 2005 is positioned in the pipe 100 . Other retaining clip options are possible.
[0093] Some embodiments may use a warning system that will alert the user and others that exhalation has not gone back through the pipe. This alarm or alerting system will have an adjustable timer of from 5 seconds to 30 seconds after which the alarm or alert will sound. The use of this alarm or alerting system will assist in the training of the user to always exhale through the device. Over time, the proper use of this device will become habit.
[0094] The exhalation filter cartridge 203 may be designed to be inserted into the series of devices.
[0095] Some embodiments may use filter media that is not in the form of a cartridge.
[0096] Although several of the embodiments have been described as using the same mouthpiece for inhalation and exhalation, one skilled in the art will recognize that separate mouthpieces may be used. Further, one skilled in the art will recognize that, in some embodiments, the inhalation path and exhalation path may not overlap.
[0097] The term “pipe” herein shall include various types of smoking devices, including bongs, hookahs, cigarettes, cigars, e-cigarettes, or the like.
[0098] It will be appreciated that smoke and odor may be visible or invisible. It will be appreciated that the term “smoke” may or may not include odor.
[0099] The foregoing description of the preferred embodiments of the present invention is by way of example only, and other variations and modifications of the above-described embodiments and methods are possible in light of the foregoing teaching. The embodiments described herein are not intended to be exhaustive or limiting. The present invention is limited only by the following claims. | A pipe comprises a combustion bowl with bowl vents; an inhalation path for drawing smoke from the combustion bowl through the bowl vents during inhalation; an exhalation filter; and an exhalation path for forcing exhaled smoke through the exhalation filter during exhalation. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multilayered optical associative memory device or an optical neural network device.
2. Description of the Prior Art
Numerous studies are known which parallelly implement large volume computation problems on a neural network utilizing the parallel property of light. Many optical computers used in those studies employ holograms, for example:
A1. Y. Owechko, "Hybrid optical and electronic associative memory", (U.S. Pat. No. 4,837,843);
A2. Y. Owechko, Optical Computing 90, 10-a-1 (1990);
A3. A. Yariv. et. al., Phys. Lett. 48, (1986) 1114;
A4. Kitayama K., et. al., IJCNN 1989 Vol. 2,465-741 (1989);
A5. E. G. Peak, D. Psaltis, Optical Engineering, Vol. 26, No. 5,428 (1987);
A6. Y. S. Abu-Mostafa, Demetri Psaltis, Sci. Am., Vol. 256, No. 3, PP 66-73 (1987).
Use of such holograms, however, leads to the problem that crosstalk might be produced upon multiplexing. This is a problem the devices being integrated and a problem an optical hologram computing system.
To solve these problems, a number of studies to realize an associative memory without use of a hologram have been proposed for example:
B1. Fisher, A. D., "Adaptive Associative-Processing Optical Computing Architectures", (U.S. Pat. No. 4,862,406);
B2. H. J. Caulfield, SPIE, 456,2, Optical Computing (1984);
B3. K. Kyuma, Optical Computing 90,10-A-2 (1990);
B4. N. H. Farhat, et. al., Applied Optics, Vol. 24, No. 10,1469 (1985);
B5. N. Mukohzaka, U.S. patent Ser. Nos. 07/203,909 filed Jun. 8, 1992 now abandoned and 07/204,350 filed Jun. 9, 1992 now abandoned (Associatron).
These prior techniques however have the following problems. Techniques of B1, B2, B3 and B5 have insufficient associative function because of being a system with a single layer. In technique B3 learning is not taken into consideration; therefore, it can not adapt to changes in environment, which is one of features of a neural network. The B1 technique of requires an electric synchronous circuit which prevents an input from being processed as an intact image (as an optical pattern), because it is combined with an AO element. The technique of B4 also requires some processing by an electric circuit.
SUMMARY OF THE INVENTION
In view of the drawbacks with the prior art, it is an object of the present invention to provide a multilayered optical neural network system capable of optically implementing two-dimensional data transfers and computations without use of a hologram and an electric circuit.
To achieve the above object, a multilayered optical neural network system according to the present invention, as shown by example in FIG. 1, comprises an input layer (including a pattern input device 8); an output layer (including an output function computing device 34); at least one hidden layer (including an output function computing device 28) provided between the input layer and the output layer; memory matrix holding means (memory matrix holding devices 18, 22) provided between respective layers for holding the weight applied to coupling between layers; correlation computing means (correlation computing devices 24, 31) for optically implementing correlation computation between an output light pattern from the previous layer and a memory matrix pattern; output function computing means (output function computing devices 28, 34) for optically computing an output function with respect to a result of the correlation computation as an output to the next stage; and memory matrix correcting means (memory matrix correcting devices 38, 42) provided between layers for optically correcting by learning a memory matrix held by said memory matrix holding means.
In accordance with one aspect of the present invention, a multilayered neural network system (for example, three layers in FIG. 2) composed of an input layer, a hidden layer, and an output layer as illustrated in FIG. 2 is constructed using an all optical type architecture without a hologram in which data transfers and computations are implemented wholly optically and in two-dimension. A learning mechanism, that constitutes an essential part of a neural network, is operable with interlayer feedback construction indispensable to a multilayered learning system, and is realized by optical computing. A multilayered computing mechanism can execute a large volume of computing volume which can not be processed by a single-layered network. As illustrated in FIG. 3, in a simple four-layered optical neural network system, the number of layers can be arbitrarily structured depending upon objects to be processed.
A neural network system of this type, which constructs a network based upon error back propagation that is adapted to feed back an erroneous output result to an input side and repeatedly weigh an input signal on the basis of the fed-back error signal for obtaining a correct output, has as a characteristic feature simplified computations such as product and sum operations and output function computations, etc., that are excellently uniform and congenial to optical computing, enabling association and recognition computations. The present invention constructs a multilayered neural network system that assures flexible computing in an all optical system using a highly parallel optical computing architecture so that computation times for learning and recalling can be shortened.
In another aspect of the present invention, particularly in the case where layers, that are separated by one or more other layers, are coupled to each other as illustrated in FIG. 4 (between an input layer and an output layer in the figure), a complicated multilayered (three layers in the figure) optical neural network system can be structured to further increase the amount of computing.
In another aspect of the present invention, the memory matrix correcting means can correct a memory matrix by optical means on the basis of signals fed from later layer memory matrix holding means (22) or the output function operating means (28), said output function differential operation means (36 or 37) for differentiating an output from said correlation operation means, and later layer correction signal holding means (memory matrix correcting device 38 or target pattern input device 13) as illustrated in FIG. 1.
In still another aspect of the present invention, said output function differential operating means is constructed with a microchannel spatial light modulator tube, mirrors, and wave plates for interlayer feedback (output differential function in particular) by optical computing with a simplified architecture.
In still another aspect of the present invention, said simple three-layered optical neural network system with a basic architecture illustrated in FIG. 4 comprises, as illustrated in FIG. 5, a multiple imaging system 10 for multiplexing and imaging an input pattern x; and input pattern converting device 12 for holding an image multiplexed and imaged; a multiple imaging system 14 for multiplexing and imaging a target pattern t, a target pattern converting device 16 for holding an image multiplexed and imaged; a first memory matrix holding device 18 for holding a memory matrix w 01 corresponding to a correlation between the input pattern x and a hidden layer output pattern u; a second memory matrix holding device 20 for holding a memory matrix w 02 corresponding to a correlation between the input pattern x and an recalling output pattern y; a third memory matrix holding device 22 for holding a memory matrix w 12 corresponding to a correlation between the hidden layer output pattern u and the recalling output pattern y; first correlation operating means 24 for optically computing a Hadamard product between images held in the input pattern converting device and the first memory matrix holding device by reading out those images in succession; a local imaging system 26 for locally imaging an image formed by the first correlation operating means for optical computing the partial sum; a first output function operating device 28 for optically computing an output function for an image locally imaged to obtain the hidden layer output pattern u, second correlation operating means 30 for optically computing a Hadamard product between images held in the input pattern converting device and the second memory matrix holding device by reading those images in succession; third correlation operating means 31 for optically computing a Hadamard product between images held in the first output function operating device and the third memory matrix holding device by reading out those images in succession; a local imaging system 32 for locally imaging images formed by the second and third correlation operating means to optically compute the partial sum between those images; a second output function operating device 34 for optically computing an output function with respect to an image locally imaged to recall the output pattern y; an output function differential operating device 36 for optically differentiating the output function; first memory matrix correcting means 38 for learning a correlation between the hidden layer and the output layer to correct the memory matrix w 12 held in the third memory matrix holding device using the images held in the first and second output function operating devices, the output function differential operating device, and the target pattern converting device; second memory matrix correcting means 40 for learning a correlation between the input layer and the output layer to correct the memory matrix w 02 held in the second memory matrix holding device using the images held in the target pattern converting device, the second output function operating device, the output function differential operating device, and the input pattern converting device; and third memory matrix correcting means 42 for learning a correlation between the input layer and the hidden layer to correct the memory matrix w 01 held in the first memory matrix holding device using the images held in the input pattern converting device, the second output function operating device, the output function differential operating device, the target pattern converting device, and the third memory matrix holding device.
Operation of the memory matrix correcting means 38 in FIG. 5 is described herein. This corresponds to the portion to correct W12 in FIG. 2 although not appearing in the same figure. Further, in FIG. 4, this corresponds to portions to calculate (t -y) f' (net 2) and ΔW12. How to realize this is actually illustrated in FIG. 16 (page 24, line 13 and thereafter). "Multi-imaging" and "local-imaging", etc., are described in U.S. Pat. No. 203,909 and U.S. Pat. No. 204,350 in detail. The basic computing of the neural network is realized by superimposing the two-dimensional patterns (multiplication of transmittances).
In another aspect of the present invention, the first memory matrix correcting means 38 comprises first multiplication means for optically implementing multiplication of transmittances of the images held in the first output function operating device, the output function differential operating device, and the target pattern converting device by reading out those images in succession; addition means for adding a result of the multiplication by the first multiplication means to the image held in the third memory matrix holding device; second multiplication means for optically implementing multiplication of transmittances of the images held in the first and second output function operating devices and the output function differential operating device by reading those images in succession; and subtraction means for subtracting a result of the multiplication by the second multiplication means from the image held in the third memory matrix holding device.
In another aspect of the present invention, the second memory matrix correcting means 40 comprises first multiplication means for optically implementing multiplication of transmittances of the images held in the target pattern converting device, the output function differential operating device, and the input pattern converting device by reading those images in succession; addition means for adding a result of the multiplication by the first multiplication means to the image held in the second memory matrix holding device; second multiplication means for optically implementing multiplication of transmittances of the images held in the first output function operating device, the output function differential operating device, and the input pattern converting device by reading those images in succession; and subtraction means for subtracting a result of the multiplication by the second multiplication means from the image held in the second memory matrix holding device.
In still another aspect of the present invention, the third memory matrix correcting means 42 comprises first multiplication means for optically implementing multiplication of transmittances of the images held in the target pattern converting device and the output function differential operating device by reading out those images in succession; second multiplication means for optically implementing multiplication of transmittances of the images held in the second output function operating device and the output function differential operating device by reading those images in succession; an operation result holding device for holding results yielded by adding successive outputs from the first multiplication means and then subtracting therefrom successive outputs from the second multiplication means; fourth correlation operating means for optically implementing a Hadamard product between the images held in the operation results holding device and the third memory matrix holding device by reading out those images in succession; a local imaging system for locally imaging an image formed by the fourth correlation operating means to optically compute the partial sum; a partial sum holding device for holding the partial sum formed by the local imaging system; fifth correlation operating means for optically implementing a Hadamard product among the images held in the partial sum holding device, the input pattern converting device, and the output function differential operating device by reading out those images in succession; and addition/subtraction means for adding/subtracting a result of the operation by the fifth correlation operating means to/from the image held in the first memory matrix holding device.
In another aspect of the present invention, the addition/subtraction means is adapted to separate the addition and the subtraction to first add a positive fraction of the operation result to the image and then subtract a negative fraction of the operation result from the image.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments will be described with reference to the drawing, wherein like elements have been denoted throughout the figures with like reference numerals, and wherein:
FIG. 1 is a block diagram illustrating the basic construction of a simple three-layered optical neural network system according to the present invention;
FIG. 2 is a block diagram illustrating the basic construction of a multilayered network system;
FIG. 3 is a block diagram illustrating the said construction of a simple four-layered optical neural network system according to the present invention;
FIG. 4 is a block diagram illustrating the said construction of a complicated three-layered optical neural network system according to the present invention;
FIGS. 5A and 5B are block diagram exemplarily illustrating a concrete construction of the aforementioned simple three-layered optical network system;
FIG. 6 is a view illustrating an optical path in the construction of an embodiment of the present invention;
FIG. 7 is a crosssectional view illustrating the basic construction of a microchannel spatial light modulator used in the embodiment of FIG. 6;
FIGS. 8 and 9 are diagrams each exemplarily illustrating an output function used in the embodiment of FIG. 6;
FIG. 10 is a diagram exemplarily illustrating the differentiated waveform of the output function;
FIGS. 11 and 12 are diagrams each exemplarily illustrating an optical system implementing the differential operation of the output function;
FIG. 13 is a view of an optical path illustrating the operation of the recall operation 1 in the aforementioned embodiment;
FIGS. 14 and 15 are views of optical paths each illustrating the operation of the recall operation 2;
FIGS. 16 and 17 are views of optical paths each illustrating the operation of the learning operation 1;
FIGS. 18 and 19 are view of optical paths each illustrating the operation of the learning operation 2;
FIGS. 20 through 24 are views of optical paths each illustrating the operation of the learning operation 3; and
FIG. 25 is a diagram exemplarily illustrating voltage setting in the microchannel spatial light modulator that attaches importance to linearly in a modification of the aforementioned embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In what follows, there will be described an embodiment of the present invention that is applied to a simple three-layered neural network system in which learning is performed on the basis of back propagation, with reference to the accompanying drawings.
The present embodiment comprises, as illustrating in FIG. 6, a lens array 50 constituting the multiple imaging system 10 shown in FIG. 5; an input pattern converting microchannel spatial light modulator (MSLM) 52 constituting the aforementioned input pattern converting device 12; a lens array 54 constituting the aforementioned multiple imaging system 14; a target pattern converting MSLM 56 constituting the aforementioned target pattern converting device 16; a memory matrix holding MSLM 58 constituting the aforementioned first memory matrix holding device 18; a memory matrix holding MSLM 60 constituting the aforementioned second memory matrix holding device 20; a memory matrix holding MSLM 62 constituting the aforementioned third memory matrix holding device 22; a laser light source 64; half mirrors 66, 68 and 70, mirrors 72, 74 and 76, a half mirror 78, and a mirror 80 all constituting together the aforementioned first correlation operating means 24; a lens array 82 constituting the aforementioned local imaging system 26; an output function operating MSLM 84 constituting the aforementioned first output function operating device 28; the laser light source 64, the half mirrors 66, 68 and 70, the mirrors 72, 74 and 78, the half mirror 78, a mirror 86, a half mirror 88, a mirror 90, and a half mirror 92 all constituting together the aforementioned second correlation operating means 30; a laser light source 96, a halfmirror 98, a mirror 100, and half mirrors 102, 106, 108 and 92 all constituting together the aforementioned third correlation operating means 31; lens arrays 110, 111 and 113 all constituting together the aforementioned local imaging system 32; an output function operating MSLM 112 constituting the aforementioned second output function operation device 34; and output function differential operating MSLM 114 constituting the aforementioned output function differential operating device; half mirrors 116 and 120 for splitting an output from the lens array 110 to the MSLMs 112 and 114; the laser source 96, the half mirror 98, the mirror 100, the half mirror 102, and a mirror 122, a half mirror 124, a mirror 126, a half mirror 128, half mirrors 130, 132 and 66, mirrors 134 and 136, and half mirrors 138 and 140 all constituting together the aforementioned first memory matrix correcting means 38; the laser light source 96, a mirror 143, and the mirror 122, the half mirror 124, the mirror 126, the half mirrors 128, 130, 132 and 68, and a laser light source 142, and the half mirror 140 all constituting together the aforementioned second memory matrix correcting means 40; and the laser light source 96, the mirrors 143 and 122, the half mirror 124, the mirror 126, the half mirror 128, the half mirrors 130, 132 and 66, the mirror 134, and a half mirror 144 and a δ operating MSLM 146, and the half mirrors 138 and 140 and the half mirrors 106, 108, 148, 150 and 152, a local imaging lens array 154, a laser light source 156, and half mirrors 158, 160 and 162, and the half mirror 68, and a partial sum holding MSLM 166, a mirror 170 and a half mirror 172 all constituting together the aforementioned third memory matrix correcting means 42.
The aforementioned first memory matrix correcting means 38 more specifically comprises the laser light source 96, the half mirror 98, the mirror 100, the half mirror 102, the mirror 122, the half mirror 124, the mirror 126, and the half mirrors 128 and 130 all constituting together first multiplication means for optically implementing multiplication of transmittance of images held by the first output function operating MSLM 84, the output function differential operating MSLM 114, and the target pattern converting MSLM 56 by successively reading out those images; the half mirrors 132 and 66, and the mirrors 134 and 136 all constituting together addition means for adding a multiplication result by the first multiplier means to an image held by the third memory matrix holding MSLM 62; the laser light source 96, the half mirror 98, the mirror 100, the half mirror 102, the mirror 122, and the half mirrors 124, 138, 140 and 130 all constituting together second multiplication means for optically implementing multiplication of transmittances of images held by the first and second output function operating MSLMs 84, 112 and the output function differential operating MSLM 114 by successively reading out those images; and the half mirrors 132 and 66, and the mirrors 134 and 136 all constituting together subtraction means for subtracting a multiplication result by the second multiplier means from an image held by the third memory matrix holding MSLM 62.
The aforementioned second memory matrix correcting means 40 more specifically comprises the laser light source 96, the half mirrors 143, 122, the half mirror 124, the mirror 126, and the half mirrors 128, 130 and 132 all constituting together first multiplication means for optically implementing multiplication of transmittances of images held by the target pattern converting MSLM 56, the output function differential operating MSLM 114, and the input pattern converting MSLM 52 by successively reading out those images; the half mirror 68 constituting addition means for adding a multiplication result by the first multiplication means to an image held by the second memory matrix holding MSLM 60; the laser light source 142, and the half mirrors 140, 130 and 132 all constituting together second multiplication means for optically implementing multiplication of transmittances of images held by the first output function operating MSLM 112, the output function differential operating MSLM 114, and the input pattern converting MSLM 52 by successively reading out those images; and the half mirror 68 constituting subtraction means for subtracting a multiplication result by the second multiplication means from an image held by the second memory matrix holding MSLM 60.
The aforementioned third memory matrix correcting means 42 more specifically comprises the laser light source 96, the mirrors 143, 122, the half mirror 124, the mirror 126, and the half mirrors 128, 130 all constituting together first multiplication means for optically implementing multiplication of transmittances of images in the target pattern converting MSLM 56 and the output function differential operating MSLM 112 by successively reading those images; the laser light source 96, the mirrors 143, 122, and the half mirrors 124, 138, 140 and 130 all constituting together second multiplication means for optically implementing multiplication of transmittances of images held by the second output function operating MSLM 112 and the output function differential operating MSLM 114 by successively reading out those images; a δ operating MSLM 146 for holding a result δ yielded by adding an output from the first multiplication means that is input thereinto through the half mirrors 130, 132 and 66, the mirror 134, and the half mirror 144 and subtracting an output from the second multiplication means all constituting together an operation result holding device; the laser light source 96, the mirror 143, and the half mirrors 106, 108, 148 and 150 all constituting together fourth correlation operating means for optically implementing a Hadamard product of images held by the δ operating MSLM 146 and the third memory matrix holding MSLM 62 by successively reading those images; the lens array 154 constituting the local imaging system for locally imaging an image formed by the fourth correlation operating means and input thereinto via the half mirror 150, the mirror 122, and the half mirrors 124, 152 to optically implement partial sum of the image locally imaged; the partial sum holding MSLM 166 for holding the partial sum formed by the lens array 154; the laser light source 156, and the half mirrors 130, 132, 68, 160, and 162 all constituting together fifth correlation operating means for optically computing a Hadamard product of images held by the partial sum holding MSLM 166, the input pattern converting MSLM 52, and the output function differential operating MSLM 122 by successively reading those images; and the half mirror 162 constituting addition/subtraction means for adding or subtracting a multiplication result by the fifth correlation operating means to or from an image held by the first memory matrix holding MSLM 58.
The aforementioned MSLMs 52, 56, 58, 60, 62, 84, 112, 114, 146 and 166 comprise, as illustrated in FIG. 7 for example, a photocathode 52A for converting an input image incident thereupon via a lens (for example 50) to a photoelectric image; a microchannel plate (MCP) 52B for multiplying the photoelectric image emitted from the photocathode 52A; a mesh electrode 52C for accelerating photoelectrons multiplied by the MCP 52B; and an electrooptic crystal 52E where an electric charge pattern is formed on an electric charge storage surface 52D located on the left side in the figure by electrons passing through the mesh electrode 52C.
In the MSLM (for example 52), the electric charge pattern is formed on the electric charge storage surface 52D of the electrooptic crystal 52E in response to the input image, in response to which pattern an electric field traversing the electrooptic crystal 52E is changed to cause the refractive index of the electrooptic crystal 52E to be changed owing to the Pockels effects. Accordingly, when the electrooptic crystal 52E is irradiated with linearly polarized laser light from the right side in the figure, reflected light from the electric charge storage surface 52D has been changed in its polarization state owing to double refraction of the electrooptic crystal 52E. Therefore, once the reflected light is transmitted through an analyzer 53, an output image having light intensity corresponding to the input image is yielded. Herein, although no polarizing plate is illustrated in FIG. 6 for simplifying the figure, there is actually provided one polarizing plate corresponding to one MSLM.
The MSLM manifests excellent functions in addition to an incoherent to coherent light converting function and a memory function, an addition/subtraction function, a real time thresholding function, and an AND operation function, etc., which are made operable by controlling electric charges under proper condition. Optical associative memory devices utilizing such functions are disclosed in Japanese Laid-Open Patent Publications Nos. 63-367437 and 64-78491.
The MSLMs and lens arrays can be used to execute the following basic operations in optical computing.
(1) MULTIPLICATION
Multiplication of transmittances of images held by the MSLMs can be implemented by successively reading those images using two or more of the MSLMs and corresponding polarizing plates.
(2) ADDITION AND SUBTRACTION
Two-dimensional addition and subtraction can be implemented by setting voltages applied to the MSLMs.
(3) Partial Sum Operation
Sum can be realized by focusing light through a lens. Partial sum can therefore be implemented using a multi-lens array or a diffraction grating.
(4) OUTPUT FUNCTION OPERATION
The output function includes a sigmoid function as illustrated in FIG. 8 and a threshold function as illustrated in FIG. 9, and other functions. MSLMs enable thresholding therein. Additionally, the input/output characteristic of the MSLM when used in a normal mode exhibits sin 2 θ which can also be used as an output function. Further, MSLMs can assure arbitrary functions based upon sin 2 θ by controlling voltage applied thereto.
(5) DIFFERENTIATION OF OUTPUT FUNCTION
DIfferentiation f'(net) on the output function in the back propagation (refer to FIG. 10) can be realized as follows for example.
EXAMPLE NO. 1
A relationship: output=sin 2 (input) is utilized.
Use of the MSLM is a normal mode presents a sin 2 curve as the input/output characteristic thereof. This leads to an input/output relationship such as illustrated in FIG. 10 by setting application voltage to the MSLM such that θ is π.
EXAMPLE NO. 2
An expression: output=input (1-input) is employed.
The expression is realizable with an optical system composed of two MSLMs 200, 202, two polarizing plate 204, 206 with polarization directions perpendicular to each other, and half mirrors 208, 210, 212 and 214, as illustrated in FIG. 11 for example. More specifically, in the case where an input x has been written in the MSLM, as the polarizing plate is rotated 90°, a light and darkness pattern is reversed to take out a pattern (1-x). Therefore, successive read out of (1-x) and x using a laser establishes operation of the following equation:
y=x(1-x)
where y is an output.
Moreover, an optical system to realize the above equation is also achievable as illustrated in FIG. 12, using an MSLM 200, two polarizing plates 204 (with a polarization direction horizontal with respect to a laser) and 206 (with a polarization direction vertical with respect to the laser), a halfwave plate 216, half mirrors 212, 214 and 218, and mirrors 220, 222, and 224. In operation, at 1 signal fraction 1 of flat light from the laser enters the optical system and at 2 a signal x written in the MSLM 200 is read out. The signal x so read out is reflected at 3 the half mirror 212 and at 4 the half mirror 218, and further reflected on the mirrors 224 and 222. Thereafter, at 5 a (1-x) fraction is taken out as the intensity through the polarizing plate 204, and at 6 the polarization direction is rotated 90° by the half wave plate 216. Further, the signal (1-x) is reflected at 7 on the mirror 220 and at 8 on the half mirror 212 to be incident upon the MSLM 200. Furthermore, at 9 the signal in the MSLM 200 is again read out and at ○ 10 the computation x (1-x) is implemented at ○ 11 the result is reflected on the half mirror 214 and thereafter taken out through the polarizing plate 206.
In the following, operation of the embodiment will be described.
It is now assumed that the input pattern is x, a hidden layer output pattern u, a recalling output pattern y, and a target pattern t. A learning pattern is expressed by a pair (x, t). A memory matrix is prepared by learning a plurality of sets of the learning patterns (x 2 , t 1 ), (x 2 , t 2 ), . . . , (x n , t n ). When an input x' is input upon recalling, an output t 0 corresponds to a strongly correlated pattern among the learned patterns x 1 . . . x n can be associated.
The operation largely comprises five groups as will be described in succession.
1 Recall Operation of the Hidden Layer Output u (Recalling Operation in FIG. 2)
The Recall Operation 1 is realized using the following equation:
u=f(ΣW.sub.01 ·X) (1)
where f is the output function, Σ is the partial sum, w 01 is a memory matrix held by the first memory matrix holding MSLM 58, and x is the input pattern.
As illustrated in FIG. 13, images x, w 01 held by the input pattern converting MSLM 52 and the first memory matrix holding MSLM 58 are successively read by laser light emitted from the laser light source 64 to implement a two-dimensional pointwise Hadamard product (multiplication of transmittances) w 01 ·x. A result of the multiplication is subjected to the partial sum Σ by the lens array 82 located on the entrance side of the first output function operating MSLM 84, and the multiplication result is further subjected to the output function f operation in the output function operating MSLM 84 to yield the hidden layer output pattern u
2 Recall Operation of the output y (Recall Operation 2 in FIG. 2)
The Recall Operation 2 is realized urging the following equation:
y=f(ΣW.sub.02 ·X+ΣW.sub.12 ·u)(2)
where w 02 is a memory matrix held by the second memory matrix holding MSLM 60 and w 12 is a memory matrix held by the third memory matrix holding MSLM 62.
For the Recall Operation 2 optical computing is implemented separately for the right side first term and for the right side second term of the equation (2).
More specifically, as illustrated in FIG. 14, images x, w 02 held in the input pattern converting MSLM 52 and the second memory matrix holing MSLM 60 are successively read out by the laser light emitted from the laser light source 64 to compute w 02 ·x. A result of the multiplication reaches the second output function operating MSLM 112 through the partial sum operating lens array 110.
In succession, as illustrated in FIG. 15, images u, w 12 held in the first output function operating MSLM 84 and the third memory matrix holding MSLM 63 are successively read out by laser light emitted from the laser light source 96 to compute w 12 ·u. A result of the multiplication reaches the second output function operating MSLM 112 through the partial sum operating lens array 110.
Thus, the operation in the parenthesis of the right side is realized. More specifically, the partial sum Σ is implemented by the lens array 110 and applied to the output function f by the second output function operating MSLM 112 to yield the recalling output pattern y.
Herein, the partial sum "net 2" of the signal to the output layer is stored in the output function differential operation MSLM 114 as indicated by a broken line in FIG. 14 for use in learning.
3 Learning Operation of Hidden Layer--Output Layer (Learning Operation 1 in FIG. 2).
The Learning Operation 1 is used to correct the memory matrix w 12 held in the third memory matrix holding MSLM 62 as expressed by the following equation:
W.sub.12 (n+1)=W.sub.12 (n)+ΔW.sub.12 (3)
Herein, n denotes the number of iteration of the learning and Δw 12 is a correction term which is expressed by the following equation:
ΔW.sub.12 =ηδ.sub.2 u=η{(t-y)f'(net 2)}u =η.sub.1 ·t·f'(net 2)u -η.sub.2 ·y·f'(net 2)·u (4)
where η, η 1 and η 2 are learning gains.
The operation of the equation (4) also implemented separately for the right side first term and the right side second term.
First, as illustrated in FIG. 16, images u, t, and f'(net) held in the first output function operating MSLM 84, the target pattern converting MSLM 56, and the output function differential operating MSLM 114 are successively read out by irradiation of the laser light emitted from the laser light source 96 to realize multiplication u·t·f'(net 2) of transmittances. A result of the operation is entered into the third memory matrix holding MSLM 62 in which the memory matrix w 12 is held to implement addition in the MSLM 62 and hence realize the right first term in the equation (4). Herein, the learning gains η 1 and η 2 are realized by controlling voltage applied to the MSLM 62 and the like.
In succession, as illustrated in FIG. 17, images u, y, and f'(net 2) held in the first output function operating MSLM 84, the second output function operating MSLM 112 and the output function differential operating MSLM 114 are successively read out by irradiation of the laser light emitted from the laser light source 96 to realize multiplication u·y·f'(net 2) of the transmittances of those images. A result of the multiplication is entered into the memory matrix holding MSLM 62 to implement subtraction therein. Hereby, the right side second term in the formula (4) is realized and hence the equation (3) is realized.
4 Learning Operation of the Input Layer--the Output Layer (Learning Operation 2 in FIG. 2)
The Learning Operation 2 is used to correct the memory matrix w 02 held in the second memory matrix holding MSLM 60 as expressed by the following equation:
W.sub.02 (n+1)=W.sub.02 (n)+ΔW.sub.02 (5)
where Δw 02 is a correction term of the memory matrix w 02 as expressed by the following equation:
ΔW.sub.02 =ηδ.sub.2 X=η{(t-y)f'(net 2)∵X =η.sub.1 ·t·f'(net 2)·X -η.sub.2 ·y·f' (net 2)·X (6)
Also, the Learning Operation 2, operation is implemented separately for the right side first term and right side second term of the equation (6).
More specifically, as illustrated in FIG. 18, images t, f'(net 2), and x held in the target pattern converting MSLM 56, the output function differential operation MSLM 114, and the input pattern converting MSLM 52 are successively read out by irradiating the laser light emitted from the laser light source 96 to realize multiplication t·f'(net 2)·x of the transmittances of the images. A result of the operation is entered into the second memory matrix holding MSLM 60 to implement addition in the MSLM 60 and hence realize a portion corresponding to the right side first term of the equation (6) in the equation (5).
In succession, as illustrated in FIG. 19, images y, f'(net 2), and x held in the second output function operating MSLM 112, the output function differential operating MSLM 114, and the input pattern converting MSLM 52 are successively read out by irradiating those MSLMs with the laser light emitted from the laser light source 142 to realize multiplication y·f'(net 2)·x of transmittances of those images. A result of the operation is entered into the second memory matrix holding MSLM 60 to implement subtraction in the MSLM 60, whereby a fraction corresponding to the right side second term of the equation (6) in the equation (5) is realized.
5 Learning Operation of the Input Layer--the Hidden Layer (Learning Operation 3 in FIG. 2)
The Learning Operation 3 is used to correct the memory matrix w 01 held in the first memory matrix holding MSLM 58 as expressed by the following equation:
W.sub.01 (n+1)=W.sub.01 (n)+ΔW.sub.01 (7)
where Δw 01 is a correction term of the memory matrix w 01 which is expressed by the following equation: ##EQU1##
It should be noticed here that Σδ 2 w 12 in the parenthesis of the equation (8) takes a positive or negative value which can not be processed intact by optical computing which takes only positive values with respect to an intensity signal. To solve this, the quantity Δw 01 is divided to positive and negative terms as expressed by the following equation, and the positive term is first added to and written into the MSLM and then the negative term is subtracted.
ΔW.sub.01 =η.sub.1 (f'(net 1) * (Σδ.sub.2 W.sub.12).sup.+ -η.sub.2 (f'(net 1) (Σδ.sub.2 w.sub.12)-(9)
More specifically, the right side first term of the equation (9) is first computed as a correction signal for the memory matrix w 01 and written into the first memory matrix holding MSLM 58, and then a result through the same route is subtracted from the memory matrix holding MSLM 58. Hereby, the desired computation is realized.
In the following a process to compute δ 2 will first be described.
Because of the computations of Δw 12 in the Learning Operation 1, is expressed by the following equation: ##EQU2##
As shown in FIGS. 20 and 21, the result is written into the δ operating MSLM 146 for addition and subtraction. Herein, since the MSLM exhibits only positive values, any negative computation result is zero. More specifically, in the computation:
(t·f'(net 2)-y·f'(net 2)),
only the positive quantities of:
(t·f'(net 2)-y·f'(net 2)),
are given as δ 2 . Accordingly, in
(y·f'(net 2)-t·f'(net 2)),
i.e., in the case where y·f'(net 2) is first added to an input into the MSLM and then t·f'(net 2) is subtracted, negative quantities of:
(t·f'(net 2)-y·f'(net 2)),
are expressed by absolute values (i.e., positive light intensity).
Then, computation Σδ 2 ·w 12 is realized, as illustrated in FIG. 22, by irradiating the third memory matrix holding MSLM 62 and the δ operating MSLM 146 with the laser light emitted from the laser light source 96, in order, to read the image w 12 and δ held in those MSLMs successively, and implementing the partial sum Σ through the lens array 154 and writing a resulting value into the partial sum holding MSLM 166.
Additionally, the computation η 1 {f'(net 1)Σ(δ 2 W 12 )·X} + is implemented as follows: similar to the route described in the "1 recalling of a hidden layer output u", net 1=Σw 01 x is computed, and a result is entered into the output function differential operating MSLM 114 to obtain f'(net 1). The result f'(net 1) is held in the output function differential operating MSLM 114 by irradiating the same MSLM with the laser light emitted from the laser light source 142 through the half mirrors 66, 68 and 70, the mirrors 72, 74 and 76, the half mirror 78, the mirror 80, the half mirror 172, and the mirror 170. Finally, images f'(net 1), x and δ w 12 held in the output function differential operating MSLM 114, the input pattern converting MSLM 52, and the partial sum holding MSLM 166 are read out successively by irradiating those MSLMs with the laser light emitted from the laser light source 156 in order, to realize the computation.
The above description is given for the right side first term, i.e., the positive term of the equation (9), and the right side second term, i.e., the negative term is also realizable with a similar process.
In the present embodiment, the multiple imaging system and the local imaging system are constructed with the lens array, respectively, to result in a simplified construction. Further, the construction of the multiple imaging system is not limited to the lens array and a diffraction grating for example may be used instead.
Additionally, although in the above embodiment the multilayerd neural network system was described as comprising three layers, i.e., the input layer, the hidden layer, and the output layer, the present invention is also applicable to a multilayered neural network system which includes two or more layers as the hidden layer, as illustrated in FIG. 3, without limitation in the number of layers to the above embodiment.
Moreover, although in the above mentioned learning was achieved with the back propagation system, learning systems to which the present invention is applicable are not limited thereto. For example, the present invention is also applicable to counter propagation where one sample is selected among those samples by allowing those samples to compete with each other, and applicable to a MADALINE that is a multilayered version of a threshold logical operation (ADALINE).
Furthermore, although in the above embodiment the MSLM was incorporated as an optical device, it requires a two-dimensional analog optical device with particularly good linearity because the dynamic range and linearity of the memory matrix excert influence on associative capability.
Accordingly, in the cases where the MSLM is incorporated, when a target pattern t is set with respect to an input pattern x formed of a plurality of signals (signals from various sensors in an object recognition system, for example), saturation of a memory matrix M is reduced to assure stable associative memory by setting the mean value of the target patterns t such that it is coincident with the means value of dynamic ranges of such memory matrixes M.
Additionally, saturation of the memory matrix M can be reduced by adjusting the initial value M(0) of the memory matrix upon starting learning such that it is coincident with the center of the dynamic ranges of the memory matrix M.
Furthermore, the MSLM exhibits an input/output function characteristic following sin 2 curve. In learning, however, higher linearily is advantageous to reduce the distortion of a signal upon convergence of the signal. For this, operating voltages (application voltage Vb to electrooptic crystal) of an input pattern displaying MSLM and a memory matrix holding MSLM may be altered from a combination (Vbw1 (upon writing), Vbe1 (upon erasing)) that is normal set voltage for maximizing a dynamic range to a combination (Vbw2, Vbe2), as illustrated in FIG. 25. Thus, a good linear input/output characteristic can be achieved by the use of a central portion.
Additionally, for the optical device there are available, besides the MSLM, a liquid crystal light value LCLV and a BSO light modulator PROM. | A multilayered optical neural network system comprise an input layer, an output layer, at least one hidden layer provided between the input layer and the output layer, a memory matrix holding device provided between the respective layers for holding weighted couplings between the layers, a correlation operating device for optically computing a correlation between an output optical pattern from the previous layer and the memory matrix pattern, an output function operating device for implementing optical computing of an output function corresponding to a result of the correlation operation, and a memory matrix correcting device provided between the respective layers for optically correcting a memory matrix held in the memory matrix holding device by a learning operation, whereby the system is capable of two-dimensional optical computing of all data transfers and operations and executing a great amount of computing without use of holograms. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application entitled “Remotely Locating and Commanding a Mobile Device,” U.S. patent application Ser. No. 12/434,586, filed May 1, 2009, the disclosure of which is herein incorporated by reference in its entirety. This application also is related to co-pending U.S. patent application entitled “Securely Locating a Device,” U.S. patent application Ser. No. 11/938,745, filed Nov. 12, 2007 and to co-pending U.S. patent application entitled “Remotely Locating and Commanding a Mobile Device,” U.S. patent application Ser. No. 12/434,582, filed May 1, 2009.
TECHNICAL FIELD
The present disclosure relates to remotely communicating with a mobile device, such as a mobile telephone or a media player, and to causing the mobile device to perform a function through the transmission of one or more remote commands.
BACKGROUND
Mobile devices have been adapted to a wide variety of applications, including computing, communication, and entertainment. For example, mobile telephones permit users to freely initiate and receive voice communications. Similarly, mobile media devices have been developed to permit users to take electronic entertainment, including audio, video, and electronic games, to even the most remote location. Further, mobile computing devices have been developed to provide users with remote access to data communications through wireless connectivity, such as over IEEE 802.11 or 3G networks. Some mobile devices, such as smart phones, support a combination of voice communications, entertainment, and mobile computing.
Because mobile devices are sized for portability, they easily can be misplaced. Also, because mobile devices often are carried to many different locations, they can be forgotten or lost. Further, because of their convenience and portability, mobile devices often are used to store a large amount of personal data. For example, a mobile device can be used to store an entire address book of contact information, electronic mail and text messages relating to business and personal matters, account information, one or more galleries of images, and a library of music. Thus, the loss of a mobile device also can incur the loss of a substantial amount of data, including sensitive personal data.
Ownership of a mobile device can be indicated in a number of ways. For example, owners can mark a mobile device with identifying information, such as a name, address, or telephone number. The mobile device can be marked physically, such as through a label or an engraving, or electronically, such as through registration information stored on the mobile device. Further, with respect to mobile telephones, an attempt can be made to recover a lost device. For example, a user can call a lost mobile telephone to speak with a finder who is willing to answer. If the finder is honest, the mobile telephone can be returned to the rightful owner. However, mobile devices and the services they provide access to often are valuable and a mobile device thus may not be returned if lost or may be intentionally stolen.
To prevent the data stored on a lost mobile device from being compromised, the data can be protected against unauthorized access in a variety of ways. For example, access to the data and/or applications can be protected through login credentials, such as a system password. The mobile device can block any access or functionality until the correct login information is supplied. Further, file encryption can be linked to a security password, such that files remain encrypted until the correct login information is supplied. A mobile device also can be locked after multiple unsuccessful attempts at access to prevent hacking. For example, a mobile device can be configured such that repeated password failures lock the mobile device to prevent any further use. Alternatively, a service provider can be contacted to disable further use of the mobile device, such as by deactivating a corresponding account.
SUMMARY
A mobile device can be remotely contacted and commanded to perform one or more operations, such as through the transmission of a message to the device. Further, before the mobile device is lost, it can be configured to support one or more remote commands. The remote commands supported can be selectively enabled by the mobile device owner. A mobile device also can support one or more remote commands by default.
The transmission of one or more remote commands to the mobile device can be initiated from a networked computing device, such as through a web service. The mobile device also can confirm receipt of one or more remote commands and can acknowledge that an associated operation or instruction has been or will be executed. For example, messages can be transmitted to and from the mobile device through a notification service implemented using a publish-subscribe (“PubSub”) framework.
The present inventors recognized a need to allow a mobile device owner to remotely issue one or more commands to the mobile device, including commands used to present a message or sound on the mobile device, to lock the mobile device, to wipe the contents of the mobile device, or to locate the mobile device. Further, the need to receive one or more messages from the mobile device acknowledging and/or responding to a remote command also was recognized. The present inventors also recognized the need to provide a web-based application configured to facilitate remote management of one or more mobile devices.
Additionally, the present inventors recognized the need to permit an existing passcode associated with a mobile device to be changed or a new passcode to be set. The present inventors further recognized the need to provide an acknowledgement indicating that a mobile device has been locked in accordance with a newly specified passcode. It also was recognized that an error message can be presented indicating that the passcode for a mobile device was not changed, such as in response to one or more predetermined conditions.
The present inventors also recognized the need to allow reconfiguring a mobile device to alter or disable support for one or more remote commands. Further, the need for the mobile device to automatically retrieve command messages also was recognized. Also, the present inventors recognized the need to permit transmitting multiple remote commands to a mobile device, such as a locate command and a message command. Additionally, the present inventors recognized the need to permit disassociating a mobile device from a remote management account, such as when ownership of the mobile device changes. Accordingly, the techniques and apparatus described here implement algorithms for remotely communicating with a mobile device to cause the mobile device to perform functions through the transmission of one or more remote commands.
In general, in one aspect, the techniques can be implemented to include receiving, by a mobile device, a remote lock command message comprising a lock command and specifying a passcode to be set, locking the mobile device in response to the received remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and generating an acknowledgement message in response to the remote lock command message.
The techniques also can be implemented such that receiving further includes accessing a subscribed topic hosted on a notification service, the subscribed topic being associated with a lock command, and retrieving the remote lock command message from the subscribed topic. Further, the techniques can be implemented such that the subscribed topic is uniquely associated with the mobile device. Additionally, the techniques can be implemented to further include determining, prior to setting the unlock passcode, that the specified passcode complies with an implemented security constraint of the mobile device.
The techniques also can be implemented to further include publishing the acknowledgement message to a notification service in substantially real time. Further, the techniques can be implemented such that generating an acknowledgement message further involves including a time stamp indicating a time at which the remote lock command message was received. Also, the techniques can be implemented such that locking the mobile device further includes locking a display associated with the mobile device such that access to one or more of information stored on the mobile device and functionality of the mobile device is blocked. Additionally, the techniques can be implemented such that setting an unlock passcode further includes initializing an unlock passcode associated with the mobile device.
In general, in another aspect, the techniques can be implemented as a computer-readable medium, tangibly encoding a computer program product comprising instructions operable to cause data processing apparatus to perform operations including accessing a subscribed topic hosted on a notification service, the subscribed topic corresponding to a mobile device, retrieving a remote lock command message included in the subscribed topic, locking the mobile device in response to the remote lock command message, and publishing an acknowledgement message to the notification service.
The techniques also can be implemented to be further operable to cause data processing apparatus to perform operations including identifying a passcode specified by the remote lock command message, detecting that the specified passcode does not comply with a security constraint implemented by the mobile device, and determining, in response to the detecting, not to reset an unlock passcode associated with the mobile device. Additionally the techniques can be implemented to be further operable to cause data processing apparatus to perform operations involving including a passcode error message in the acknowledgement message. Further, the techniques can be implemented to be further operable to include locking the mobile device by locking a display such that access to one or more of information stored on the mobile device and functionality of the mobile device is blocked. Additionally, the techniques can be implemented to be further operable to cause data processing apparatus to perform operations including establishing a connection to the notification service over a wireless data connection.
The techniques also can be implemented to be further operable to cause data processing apparatus to perform operations involving including a time stamp in the acknowledgement message indicating a time at which the remote lock command message was executed and including an indication that the mobile device was locked in the acknowledgement message. Further, the techniques can be implemented such that the subscribed topic is included in a command collection associated with the notification service that uniquely corresponds to the mobile device. Additionally, the techniques can be implemented to be further operable to cause data processing apparatus to perform operations including resetting an unlock password associated with the mobile device based on the specified passcode.
In general, in another aspect, the subject matter can be implemented as a system including a server hosting a notification service including a plurality of topics and a mobile device including processor electronics configured to perform operations including accessing a subscribed topic hosted on the notification service, the subscribed topic corresponding to the mobile device, opening a remote lock command message included in the subscribed topic, the remote lock command message comprising a lock command and a specified passcode, locking the mobile device in response to the remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and publishing an acknowledgement message to the notification service.
The system also can be implemented such that the processor electronics are further configured to perform operations involving including in the acknowledgement message an indication confirming that the unlock passcode has been set to the specified passcode and a time stamp identifying a time at which the remote lock command message was received.
The techniques described in this specification can be implemented to realize one or more of the following advantages. For example, the techniques can be implemented such that the location of a lost mobile device can be remotely requested and acquired. The techniques also can be implemented to permit transmitting one or more remote commands to a mobile device using a store and forward message framework. The remote commands can include a message command, a locate command, a sound command, a lock command, and a wipe command. Further, a PubSub model can be employed to facilitate communications between a command application and a mobile device, such that the mobile device can access a subscribed node when data communications are available. Additionally, the techniques can be implemented to permit transmitting information and/or acknowledgement messages from the mobile device in response to a remote command. The techniques also can be implemented such that a communication node monitored by a mobile device can be automatically created when the associated mobile device account is created. The techniques further can be implemented to permit delivering a remote command to a mobile device and receiving a response from the mobile device in near real-time.
The techniques also can be implemented to permit specifying a new passcode in conjunction with a remote lock command. Further, the techniques can be implemented such that the passcode is not changed by a lock command if a more complex passcode constraint has been specified on the device. The techniques also can be implemented such that one or more other remote commands can be executed after a remote lock command. Additionally, the techniques can be implemented such that the device always enters a locked state in response to receiving a remote lock command.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplary computing environment that includes mobile devices and a notification server.
FIG. 2 shows a flow diagram describing an exemplary process for linking a mobile device with a remote management account.
FIG. 3 shows a flow diagram describing an exemplary process for remotely commanding a mobile device.
FIG. 4 shows a flow diagram describing an exemplary process for receiving a remote command by a mobile device.
FIGS. 5-9 show flow diagrams describing exemplary processes for executing remote commands by a mobile device.
FIGS. 10-11 show exemplary user interfaces depicting the location reported by a mobile device in response to a locate command.
FIG. 12 shows a mobile device displaying an exemplary message in response to a message command.
FIGS. 13A and B show exemplary mobile device interfaces presented in response to an executed remote lock command.
FIG. 14 shows a flow diagram describing an exemplary process for processing a remote command message by a mobile device.
FIG. 15 shows an exemplary notification service, in which a unique command collection topic has been created for each subscribing mobile device.
Like reference symbols indicate like elements throughout the specification and drawings.
DETAILED DESCRIPTION
FIG. 1 shows an exemplary computing environment that includes mobile devices and a notification server. A communication network 105 connects the devices and applications hosted in the computing environment 100 . The communication network 105 can be any type of network, including a local area network (“LAN”), such as an intranet, and a wide area network (“WAN”), such as the internet. Further, the communication network 105 can be a public network, a private network, or a combination thereof. The communication network 105 also can be implemented using any type or types of physical media, including wired communication paths and wireless communication paths associated with multiple service providers. Additionally, the communication network 105 can be configured to support the transmission of messages formatted using a variety of protocols.
A user station 110 can be configured to operate in the computing environment 100 . The user station 110 can be any computing device that can be configured to communicate with a web-enabled application, such as through a web browser. For example, the user station 110 can be a personal computing device, such as a desktop or workstation, or a portable computing device, such as a laptop or smart phone. The user station 110 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a touch screen, and a microphone. The user station 110 also can include an output interface through which output can be presented, including one or more of a display, one or more speakers, and a haptic interface.
The user station 110 further can include a network connection to the communication network 105 . The network connection can be implemented through a wired or wireless interface, and can support bi-directional communication between the user station 110 and one or more other computing devices over the communication network 105 . Also, the user station 110 includes an interface application, such as a web browser or custom application, for communicating with a web-enabled application.
An application server 115 also can be configured to operate in the computing environment 100 . The application server 115 can be any computing device that can be configured to host one or more applications. For example, the application server 115 can be a server, a workstation, or a personal computer. In some implementations, the application server 115 can be configured as a collection of computing devices, e.g. servers, sited in one or more locations. The application server 115 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a touch screen, and a microphone. The application server 115 also can include an output interface through which output can be presented, including one or more of a display, a haptic interface, and one or more speakers.
The application server 115 further can include a network connection to the communication network 105 . The network connection can be implemented through a wired or wireless interface, and can support bi-directional communication between the application server 115 and one or more other computing devices over the communication network 105 . Further, the application server 115 can be configured to host one or more applications. For example, the application server 115 can be configured to host a remote management application that facilitates communication with one or more mobile devices associated with an account. The mobile devices and the application server 115 can operate within a remote management framework to execute remote management functions. The application server 115 also can be configured to host a notification service application configured to support bi-directional communication over the communication network 105 between multiple communication devices included in the computing system 100 . For example, the notification service application can permit a variety of messages to be transmitted and received by multiple computing devices.
FIG. 15 shows an example implementation, in which the notification service 1505 can include a defined namespace, in which a unique command collection topic ( 1520 A- 1520 C) can be created for each subscribing mobile device ( 1510 - 1512 ). A unique identifier (e.g. 1524 A) can be used to associate a subscribing mobile device (e.g. 1510 ) with the corresponding command collection topic (e.g. 1520 A), such as an assigned number or address. The unique identifier also can be embedded in a Uniform Resource Identifier (URI) that is associated with a subscribed command collection topic. Further, one or more command nodes ( 1521 - 1523 ) can be created below a command collection topic, such that each command node corresponds to a particular remote command type. For example, a command collection topic can include a separate command node for each of: locate commands ( 1521 A), message commands ( 1521 C), sound commands ( 1521 B), directory listing commands ( 1521 D), file retrieval commands ( 1522 A), screen lock commands ( 1522 C), and wipe commands ( 1522 B).
Through the use of separate command nodes, multiple commands can be transmitted to a mobile device substantially simultaneously. In some implementations, if multiple commands are received in a command collection topic, server time stamps can be compared to determine an order of execution. In some other implementations, an order of command execution can be determined based on command type. For example, if a wipe command is received in conjunction with one or more other remote commands, the wipe command can be performed last.
Through the notification service, a publisher, such as a remote management application, can publish a remote command message to a command collection topic that is associated with a particular mobile device. When a remote command message is published to the command collection topic, a notification message can be transmitted to the subscribing mobile device. The mobile device can then access the subscribed topic and retrieve one or more published messages. Thus, communication between the publisher and the mobile device can be decoupled. Further, the remote command message can be published to the appropriate command node of the command collection topic. Additionally, a mobile device receiving a remote command message can publish a response to a result topic hosted by the notification service. A publisher, such as a remote management application, can subscribe to the result topic and can receive any published response messages.
Further, the computing environment 100 can include one or more mobile devices, such as a mobile telephone 120 , a digital media player 125 , and a laptop computer 130 . Each of the mobile devices included in the computing environment 100 can include a network interface configured to establish a connection to the communication network 105 . For example, the mobile telephone 120 can establish a cellular (e.g., 3G or 4G) network connection that provides data access to the communication network 105 . Further, the digital media player 125 can establish an IEEE 802.11 (i.e., Wi-Fi or WLAN) network connection to the communication network 105 . Also, the laptop computer 130 can be configured to establish a connection to the communication network 105 based on either or both of the IEEE 802.16 (i.e., wireless broadband or WiBB) and the IEEE 802.11 standards.
Each of the mobile devices 120 , 125 , and 130 also can be configured to communicate with the notification service application hosted by the application server 115 to publish and receive messages. Further, each of the mobile devices 120 , 125 , and 130 can be configured to execute a remote management application or a remote management function responsive to a remote command received through the notification service application. In some implementations, the remote management application can be integrated with the operating system of the mobile device.
A mobile device can execute a remote command to perform one or more associated functions. For example, the remote commands can include locate commands, message commands, sound commands, directory listing commands, file retrieval commands, lock commands, and wipe commands. Some remote commands can be used to output a notification from a mobile device. For example, a sound command can cause a mobile device to output an auditory alert. Further, a message command can be used to present a text-based message on the display of a mobile device. Some other remote commands can be used to perform file-based functions. For example, a wipe command can be used to delete one or more items of data stored on the mobile device. A directory listing command can cause a mobile device to return data identifying all, or a portion of, the file directory structure associated with the storage of the mobile device. Additionally, a file retrieval command can be used to retrieve a copy of one or more files from a mobile device. Still other remote commands can be used to monitor a mobile device. For example, a locate command can cause a mobile device to transmit a message indicating its location at the time the locate command is executed. Further, a usage command can cause a mobile device to transmit a message identifying usage data for a period of time, such as calls placed or received. The period of time can be predetermined or can be specified in the usage command. Additionally, a lock command can be used to remotely secure a mobile device, such as to prevent access to functions and/or stored information by an unauthorized individual.
Additionally, each of the mobile devices 120 , 125 , and 130 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a keypad, a touch screen, a scroll wheel, general and special purpose buttons, a stylus, and a microphone. Each of the mobile devices 120 , 125 , and 130 also can include an output interface through which output can be presented, including one or more of a display, one or more speakers, and a haptic interface. Further, a location interface, such as a Global Positioning System (GPS) processor, also can be included in one or more of the mobile devices 120 , 125 , and 130 to provide location information, e.g., an indication of current location. In some implementations, general or special purpose processors included in one or more of the mobile devices 120 , 125 , and 130 can be configured to perform location estimation, such as through base station triangulation.
FIG. 2 shows a flow diagram describing an exemplary process for linking a mobile device with a remote management account. A mobile device can be linked with any remote management account to which the mobile device owner has access. In some implementations, a mobile device can be linked with only one remote management account at a time. Thus, in order to establish a link between a mobile device and a remote management account, any previous link with a different remote management account must be broken. Alternatively, the act of linking a mobile device with a remote management account can cause any previous link with a different remote management account to be broken. In some implementations, a link between a mobile device and a corresponding remote management account also can be broken without establishing a link with a new remote management account. For example, if a mobile device is being sold or otherwise transferred to a new owner, the link between the mobile device and the existing remote management account can be broken. The mobile device subsequently can be linked to a remote management account associated with the new owner. However, a mobile device cannot be remotely managed when it is not linked with a remote management account.
In order to establish a link with a remote management account, a remote management application can be initialized on the mobile device ( 205 ). A remote management application can be included on the mobile device as part of the operating system or as a preinstalled application. Alternatively, the remote management application can be downloaded and installed by a user. Once initialized, the remote management application can cause the mobile device to establish a connection to a corresponding remote management server.
Access information can be provided to the remote management server to identify the remote management account to which the mobile device is to be linked ( 210 ). For example, a username and password corresponding to a remote management account can be entered, such as in response to a prompt by the server. The username and password can uniquely identify a remote management account hosted by the remote management server. Any unique identifier can be used to indicate a specific remote management account hosted by the remote management server.
Information uniquely identifying the mobile device further can be obtained by the remote management server ( 215 ). In some implementations, a serial number, a telephone number, a Subscriber Identity Module (SIM) card, a Media Access Control (MAC) address, an International Mobile Equipment Identity (IMEI), or other such identifier can be used to identify the mobile device. In some other implementations, the information identifying the mobile device can be a unique device identifier (UDID), which can be a hash, e.g. generated using a Secure Hash Algorithm, of hardware identifiers associated with the mobile device. Further, the unique identifier can be obtained from the mobile device automatically. Thus, data entry errors can be avoided. Once identified, the mobile device can be associated with the remote management account ( 220 ).
Further, the mobile device can subscribe to a command collection topic ( 225 ). The command collection topic can be specific to the mobile device, such that only messages intended for the mobile device are published to the command collection topic. Also, access to the command collection topic can be granted only to the mobile device, which can authenticate with the notification service based on the previously determined unique identifier. In some implementations, the notification service can be hosted on the remote management server. In other implementations, the notification service can be hosted on one or more servers separate from the remote management server. When the mobile device subscribes to the command collection topic, one or more command nodes (or child nodes) can be created to receive messages published by the notification service. For example, the command collection topic can include a command node for each type of remote command message that the mobile device can receive, such as locate commands, sound commands, message commands, screen lock commands, directory listing commands, file retrieval commands, and wipe commands.
Additionally, it can be determined whether one or more remote management settings associated with the mobile device are to be changed ( 230 ). The remote management functions associated with the mobile device initially can be configured in accordance with default settings. For example, one or more of the remote management commands, such as the wipe and sound commands, can be enabled by default, while one or more other remote management commands, such as the locate command, can be disabled by default. A remote management command will not be executed by the mobile device unless it has been enabled. Accordingly, the mobile device owner's privacy can be protected in the default mobile device configuration because location information cannot be remotely obtained from the mobile device. Further, in some implementations, one or more of the remote management commands, e.g. the message command, can be permanently enabled, such that a mobile device owner cannot disable the command.
At the time the mobile device is associated with a remote management account, the mobile device owner can be prompted to review the remote command settings. If the mobile device owner elects not to change the remote command settings, the initialization process can be terminated. Alternatively, if the mobile device owner elects to change the remote command settings, the current remote command settings can be displayed so that the mobile device owner can alter one or more of the remote management settings ( 235 ). For example, the mobile device owner can provide input to enable the locate command so that the mobile device can be remotely located.
In some implementations, the remote command settings can be accessed at any time through an operating system menu item, such as preferences or contacts. Alternatively or additionally, the remote command settings can be accessed through the remote management application. Once the remote command settings have been set, the initialization process can be terminated.
FIG. 3 shows a flow diagram describing an exemplary process for remotely commanding a mobile device. A remote management application can be configured to remotely command one or more linked mobile devices by publishing remote command messages to a notification service. In some implementations, the remote management application can be a web-based application hosted on one or more servers.
A remote management account owner can login to a remote management account by accessing the remote management application and providing login credentials, such as a username and password ( 305 ). A remote management account can be established through a registration process at any time, even if no mobile devices are being linked with the account. In some implementations, the login process can be secured, such as by encrypting one or more items of login information or by establishing a secured connection. Further, in some implementations, additional or different login credentials can be required in order to access a remote management account.
Once access to a remote management account has been granted, a list of mobile devices linked with the remote management account can be presented ( 310 ). The list of mobile devices identifies each of the managed devices associated with the remote management account. Each mobile device can be uniquely identified through one or more items of information, including one or more of an icon identifying the device, a device type, a model, a serial number, a telephone number, and a nickname. Further, the list of mobile devices also can indicate, for each device, whether the device is currently reachable or online. If a mobile device associated with the account has been wiped, the mobile device can be displayed in the list of mobile devices with an indication that the device can no longer be managed. In some implementations, a mobile device also can be associated with a remote management account through the account interface, such as during account registration.
A mobile device can be selected from the list of managed devices ( 315 ). For example, the account owner can select a mobile device that has been misplaced. The mobile device can be selected by clicking on a corresponding icon or item of information included in the list of managed devices. One or more remote commands available for the selected mobile device also can be presented ( 320 ). In some implementations, all remote commands can be presented along with indicators identifying which remote commands have been enabled for the mobile device. In some other implementations, only the remote commands that have been enable are presented. Further, in some implementations, one or more remote commands also can be enabled at the account level, i.e. through the remote management account, for execution on a mobile device. For example, the mobile device and remote management application can be configured to permit one or more remote commands to be enabled through the remote management account if additional authentication information can be verified. Additionally, one or more remote commands, e.g. the locate command, can be enabled only at the device level, i.e. from the mobile device. Thus, the privacy of the mobile device owner can be safeguarded.
A remote command to be executed by the mobile device can be selected from the available remote commands ( 325 ). Based on the remote command selected, the remote management application can prompt the account owner for one or more items of information. For example, if the message command is selected, the remote management application can prompt the account owner to provide a message to be displayed on the mobile device. Alternatively, if the wipe command is selected, the remote management application can prompt the account owner to confirm that a wipe command is to be sent to the mobile device. Other remote commands can be initiated upon selection, without prompting the account owner for additional information. For example, the locate command can be initiated in response to its selection.
The remote management application can generate and transmit the selected remote command to the notification service. For example, the remote management application can have an Extensible Messaging and Presence Protocol (XMPP) connection to the notification service and can send a publish message to the corresponding command node of the command collection topic associated with the mobile device. The notification service can publish the remote command and send a notification message to the mobile device subscribing to the command collection topic.
After a remote command has been initiated, it can be determined whether another command is to be generated ( 330 ). Any number of commands can be sent to a mobile device. For example, a message command can be sent to present a message on the display of the mobile device and a sound command can be sent to provide an audible alert so that the mobile device may be noticed. However, after a wipe command has been executed, no additional commands can be sent to a mobile device until it has been reconfigured. If another command is to be generated, it further can be determined whether the command is intended for the same mobile device ( 335 ). If another command is to be generated for the same mobile device, the remote command can be selected from the available remote commands for that mobile device ( 325 ). Alternately, if the next command is intended for a different mobile device, the list of mobile devices associated with the remote management account can be presented ( 310 ).
If another command is not desired, any result messages associated with the remote management account can be accessed ( 340 ). A mobile device receiving a remote command can publish a result message indicating that the command is being executed and providing any information requested by the command. Further, the remote management account can specify a result topic with the remote command to which the mobile device is to publish the result message. If the mobile device is connected to a data network when the remote command message is published, the corresponding result message can be published by the mobile device to the result topic in real-time or near real-time. Alternatively, if the mobile device is powered off or not connected to a data network when the remote command message is published, a result message will not be published until after the mobile device establishes a connection to a data network and retrieves the remote command for execution.
FIG. 4 shows a flow diagram describing an exemplary processes for receiving a remote command by a mobile device. Some mobile devices, such as mobile telephones, can have a persistent wireless network connection, such as a (TCP) connection, whenever they are powered on and in a service area. Some other mobile devices, such as digital media players, can have a wireless network connection only when they are within range of an access point, such as a Wi-Fi base station, and the wireless network connection has been enabled. Further, push services for a mobile device can be turned off, e.g. to preserve battery life. Thus, a mobile device can be configured to establish a network connection at a predetermined interval, such as every thirty minutes, to receive remote management commands. Additionally, in the event a mobile device is configured to establish a network connection only in response to a manual command, the mobile device nonetheless can be configured to automatically establish a network connection in support of remote management. For example, a network connection can be established once an hour to check for remote command messages and then torn down. Thus, if the mobile device is lost and a network connection cannot be manually triggered, it is still possible for one or more remote management commands to be received by the mobile device.
A mobile device can access a notification service hosting a command collection topic to which the mobile device subscribes ( 405 ). For example, the mobile device can access a URI associated with the notification service and can perform an authentication process. Once authenticated, the mobile device can access a subscribed command collection topic. The command collection topic can be uniquely associated with the mobile device and can include one or more command nodes, each of which can receive a particular type of command message. The mobile device can be configured to access the notification service upon reestablishing a data network connection, such as when the mobile device is first powered on in an area in which data network access is available. Additionally, the mobile device can be configured to access the notification service in response to receiving a notification that a message has been published to a subscribed command topic.
Once the mobile device has accessed the command collection topic, each of the command nodes included in the topic can be polled to determine whether one or more new remote command messages have been received ( 410 ). In some implementations, the mobile device can be configured to compare any remote command messages included in the command collection topic to remote command messages cached by the mobile device. If a remote command message does not exist in the cache, the mobile device can treat the message as new. If no new remote command messages have been received, the mobile device can disconnect from the notification service ( 415 ).
Alternatively, if a new remote command message is detected in the command collection topic, the mobile device can retrieve the new remote command message ( 420 ). In some implementations, if more than one new remote command message exists in the command collection topic, the remote command messages can be retrieved in order based on server time stamps, command message type, or a combination thereof. For example, the mobile device can be configured to retrieve a wipe command last, as execution of the wipe command will preclude the execution of any remaining commands.
The remote command message can include general parameters to be used in executing the command and response, such as a server time stamp, a result topic to which a result message is to be published, and a command identifier. One or more command specific parameters also can be included for a particular command type. For example, a message command can include parameters identifying the message to be displayed. The parameters can be expressed using any data construct, including a delineated list, data fields, or key-value pairs. In some implementations, the server time stamp can be an XMPP standard time stamp in the format yyyy-MM-dd′T′HH:mm:ss.SSS′Z. Further, the server time stamp can be used to calculate the duration between transmission of the remote command message and execution of the associated command.
The mobile device can evaluate a retrieved remote command message to determine whether the associated command is understood ( 425 ). For example, a mobile device may not understand a command that is associated with a more recent version of an operating system or that requires functionality not included in the mobile device. If the mobile device does not understand the command associated with the retrieved remote command message, the mobile device can publish a message to a result topic indicating that the command was not understood ( 430 ). The result topic can be a predetermined result topic associated with the mobile device or a result topic identified in the remote command message. The mobile device further can determine whether the command collection topic includes a new command message ( 410 ).
If the command associated with the retrieved remote command message is understood, the mobile device can determine whether the command also is enabled ( 435 ). For example, one or more of the commands that can be executed by a mobile device can be disabled, either through user action or in accordance with default settings. If the command has been disabled, the mobile device can publish a message to the result topic indicating that the command has been disabled ( 440 ). The mobile device further can determine whether the command collection topic includes a new command message ( 410 ).
If the mobile device determines that the command is enabled, the mobile device can publish an acknowledgement message to the result topic ( 445 ). The result topic can be specified in the command message or can be a predetermined result topic. The acknowledgement message can indicate the result of the command and the time at which command execution was initiated. Also, the acknowledgement message can be published before command execution for some commands, such as the wipe command, the sound command, and the message command, to indicate that the command will be executed. For other commands, such as the location command and the lock command, the acknowledgement message can be published after the command has been executed. For example, the acknowledgement message corresponding to the location command includes data generated during command execution that identifies the location of the mobile device.
The mobile device also can execute the command identified by the remote command message ( 450 ). For example, the sound command can be executed by outputting an audible alert, such as one or more sounds played at a specified volume for a specified duration. In some implementations, the audible alert also can be delayed, e.g. for a predetermined time after the command is transmitted, and/or repeated one or more times. The message command can be executed by outputting a message, such as text, to a display included in the mobile device. The lock command can be executed to lock the screen of the mobile device and also to permit changing the passcode that must be entered to unlock the device. Further, execution of the wipe command can cause one or more items of data to be deleted from the mobile device. In some implementations, the type of data or level of wipe can be selected by the mobile device owner. In other implementations, executing the wipe command can cause the mobile device to be restored to a default state. Additionally, execution of the locate command can cause the mobile device to identify its location, based on the geographic reference information available to the mobile device at the time the command is executed. Except in the case of a wipe command, after the command has been executed the mobile device can determine whether another new message exists in the command collection topic ( 410 ).
FIG. 5 shows a flow diagram describing an exemplary process for executing a sound command by a mobile device. The mobile device can receive a sound command indicating that an audible alert is to be output ( 510 ). As described above, a remote command message corresponding to the sound command can be retrieved from a sound command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the sound command is both recognized and enabled on the mobile device. If the mobile device determines that the sound command is not recognized or is not enabled, the command is ignored.
In response to the sound command, the mobile device can determine the sound to be played ( 515 ). In some implementations, the sound command can indicate that a predetermined audible alert is to be played. The predetermined audible alert can be characterized by one or more predetermined sounds and a predetermined duration. In some other implementations, the sound command can include one or more parameters specifying characteristics of the audible alert, such as one or more sounds to be played, a volume, a duration, whether the audible alert is to be repeated, and whether the audible alert is to be output continuously or periodically.
The one or more sounds representing the audible alert can then be output by the mobile device ( 520 ). Further, the mobile device can publish a result message to the notification service ( 525 ). The result message can be published to a result topic, e.g. a result topic specified by the command message, indicating that the audible alert has been or will be output. In some implementations, the result message can include one or more items of data, such as the time at which the command was executed and the characteristics of the audible alert.
FIG. 6 shows a flow diagram describing an exemplary process for executing a message command by a mobile device. The mobile device can receive a message command indicating that a message is to be presented on a display of the mobile device ( 605 ). For example, the message can indicate contact information that can be used to coordinate the return of the mobile device. As described above, a remote command message corresponding to the message command can be retrieved from a message command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the message command is both recognized and enabled on the mobile device. If the mobile device determines that the message command is not recognized or is not enabled, the command is ignored.
The mobile device can determine the message to be displayed ( 610 ). For example, the received message command can include the text of the message to be presented. In some implementations, the message command also can specify the message format, including one or more of font, font size, text color, background, and graphics. Further, one or more restrictions can be placed on the message, such as the number of characters or message size, to ensure that the message can be displayed in its entirety on a single screen and to reduce the overhead associated with the message command. The message identified by the message command can be presented on the display of the mobile device ( 615 ). The message can be displayed above all other items presented on the display, such that the entire message is visible and uninterrupted. Further, the message can be displayed even if the mobile device is locked or if a screensaver is active.
The mobile device also can publish a result message to a result topic associated with the notification service ( 620 ). For example, a result topic can be specified by the message command. The result message can indicate that the message was displayed on the mobile device and the time at which the message was displayed. Further, the result message also can echo back the message that was displayed on the mobile device. After the message is displayed, input can be received by the mobile device to cancel the message ( 625 ). For example, when the mobile device is found, the message can be turned off in response to an action, such as a button push.
FIG. 7 shows a flow diagram describing an exemplary process for executing a wipe command by a mobile device. The mobile device can receive a wipe command indicating that one or more items of data are to be deleted from the mobile device ( 705 ). As described above, a remote command message including the wipe command can be retrieved from a wipe command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the wipe command is both recognized and enabled on the mobile device. If the mobile device determines that the wipe command is not recognized or is not enabled, the command is ignored.
In response to the wipe command, the mobile device can request to unsubscribe from the command collection topic ( 710 ). As a result of unsubscribing, all of the messages in the command nodes corresponding to the command collection topic can be deleted. In some implementations, the mobile device also can be removed from the device listing of the remote management account. In some other implementations, the mobile device can be presented in the device listing as no longer being able to be managed (or as a dead device). The mobile device can determine whether the attempt to unsubscribe from the command collection topic was successful ( 715 ). If the mobile device did not successfully unsubscribe from the command collection topic, the mobile device can repeat the request to unsubscribe ( 710 ).
If the mobile device successfully unsubscribed from the command collection topic, the mobile device can publish a response to the result topic ( 720 ). The response can indicate that the wipe process has been initiated. Further, the response also can indicate when the wipe process was initiated. In some implementations, an electronic mail (email) message also can be generated by the remote management application to indicate that the wipe process has been initiated. For example, an email message announcing the wipe procedure can be addressed to an email account associated with the remote management account owner. Once the response has been published, the mobile device can execute the wipe command ( 725 ).
In some implementations, the level of wipe to be performed can be specified in the wipe command. For example, the mobile device can be wiped to return it to the original factory settings and to delete all user data. In one alternative, the mobile device can be wiped to render it inert, such that system data must be restored before the mobile device is once again functional. In another alternative, the wipe command can specify one or more types of data to be wiped, such as electronic mail messages, images, and contacts. Any number of categories can be specified for deletion using a custom wipe command. Once the wipe procedure has been performed, the mobile device is no longer subscribed to the command collection topic and thus cannot receive any additional remote commands.
FIG. 8 shows a flow diagram describing an exemplary process for executing a lock command by a mobile device. Upon receiving a lock command message, a mobile device enters a locked state, such as by locking the screen and requiring the entry of a valid passcode before access to device functionality or stored information is once again permitted. As with other commands, the mobile device that is to receive the remote lock command can be selected in the remote management application. A lock command can be specified in the interface corresponding to the mobile device to initiate sending the remote lock command message ( 805 ). For instance, a lock button or other such interface command tool can be selected, e.g. using a mouse or touch input, to initiate the lock operation.
A lock command interface can be presented to facilitate execution of the remote lock command ( 810 ). For instance, the lock command interface can prompt the user to input and confirm a new passcode, e.g. a four-digit personal identification number (PIN), that will be required to unlock the mobile device after the lock command is executed. The new passcode can be used to set an initial passcode if one was not previously required to access the mobile device or to reset the current passcode. The new passcode can be configured in accordance with a simple (or base) security constraint utilized as a default by the mobile device. In some implementations, the lock command interface also can be configured to prompt the user to enter the current passcode for validation. The information entered into the lock command interface can be used to generate the remote lock command message.
In some other implementations, the lock command interface can indicate that a complex security constraint has been implemented on the mobile device. For instance, the mobile device can publish a message indicating that the default security constraint, e.g. a simple constraint, has been replaced by a more complex security constraint intended to provide a higher standard of security for the mobile device. In some implementations, the lock command interface can indicate that, as a result of the more complex security constraint implemented on the mobile device, the passcode cannot be changed remotely. For instance, a lock button or other such binary command tool can be presented in the lock command interface in place of the prompt for a new passcode. Alternatively, the lock command interface can be adapted to prompt the user to input a new passcode that conforms to the more complex security constraint that has been enacted. If the security constraint is known, the new passcode can be validated against the constraint and included in the remote lock command message for use in resetting the passcode on the mobile device.
Further, the remote lock command message can be published ( 815 ). For instance, the remote management application can be configured to transmit the remote lock command message to a remote lock topic associated with a command collection of a notification service that corresponds to the mobile device. Once published, the remote lock command message can be delivered to the mobile device ( 820 ). If the mobile device is on-line, i.e., has a current data connection that permits communication with the notification service, the remote lock command message can be transferred to the mobile device substantially in real-time. Otherwise, the remote lock command message can be queued at the notification service and delivered to the mobile device upon the restoration of communication with the notification service.
The passcode specified by the remote lock command message can be evaluated to determine whether it complies with the presently implemented security constraint ( 825 ). For instance, if a more complex security constraint has been implemented, the remote management application may not have been updated to reflect the change and the specified passcode could fail to meet the requirements of the more complex constraint. If a more complex security constraint has not been implemented, the remote lock command can be executed to lock the mobile device and to reset the passcode ( 830 ). For instance, a private framework on the mobile device can be accessed to cause the mobile device passcode to be reset to the passcode specified in the remote lock command message. Once the passcode has been reset and the mobile device has been locked, the newly specified password must be entered to unlock the device. Alternatively, if a more complex security constraint has been implemented, the lock command specified in the remote lock command message can be executed without resetting the passcode ( 835 ). Thus, the mobile device can be locked and the existing passcode, which conforms to the more complex constraint, is required to unlock the device.
Additionally, a message acknowledging the remote lock command message can be published to the notification service ( 840 ). The acknowledgement message can be published before or after the lock command is executed by the mobile device. If no errors are encountered, the acknowledgment message can confirm that the mobile device, e.g. the screen, was locked and that the passcode was set to the passcode specified by the lock command. Further, the acknowledgement can include a time stamp, e.g. indicating the time at which the mobile device received the remote lock command message or the time at which the mobile device was locked. In some implementations, an email message can be generated based on the published acknowledgement and can be transmitted to an email account associated with the user.
Alternatively, if one or more errors are encountered during the lock operation, the acknowledgement message can indicate whether the mobile device was locked and can include a time stamp, e.g. indicating the time at which the lock command was received. Further, the acknowledgement message can indicate the type of error encountered, e.g. passcode reset failure, and the reason for the error. For instance, the passcode reset can fail if the passcode included in the remote lock command message fails the security (or passcode) constraint that has been implemented by the mobile device. If a more complex or rigorous constraint has been implemented, the security level of the mobile device can be maintained by preventing a change to the passcode specified by the remote lock command message. In some implementations, details regarding the currently enacted security constraint can be transmitted to the user, such as in the published acknowledgement message, or in a separate published message or email. An error also can arise in response to other circumstances, such as if the remote lock command message fails to specify a new passcode, if the previous passcode used for validation was incorrect, or if the message is partially or entirely corrupted. Despite the detection of one or more errors, the mobile device can be locked in response to the remote lock command message.
FIG. 9 shows a flow diagram describing an exemplary process for executing a locate command by a mobile device. The mobile device can receive a locate command requesting the present location of the mobile device ( 905 ). As described above, a remote command message including the locate command can be retrieved from a locate command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the locate command is both recognized and enabled on the mobile device. If the mobile device determines that the locate command is not recognized or is not enabled, the command is ignored.
In response to receiving the locate command, the mobile device can determine its present location ( 910 ). For example, the mobile device can use a location process or application programming interface (API) to retrieve the available data that most accurately describes its location. If the mobile device includes a Global Positioning System (GPS) chip, the mobile device can retrieve the GPS coordinates identifying its present location. If the mobile device does not include a GPS chip, or if GPS coordinates are not available, the mobile device can determine its location through other means. For example, if the mobile device is configured to communicate on a wireless telecommunications network, the mobile device can estimate its location using cellular tower triangulation. Alternatively, if the mobile device is configured to communicate using a Wi-Fi connection, the mobile device can estimate its location in accordance the nearest Wi-Fi base station. The mobile device also can use any other technique known in the art for determining or estimating its location.
The mobile device also can be configured to determine one or more times associated with the locate command ( 915 ). For example, the mobile device can determine the time at which the locate command was received. Further, the mobile device can determine the time at which the locate command was processed to determine the location information.
Once the mobile device has determined the location information, the mobile device can publish a result message to the result topic ( 920 ). The result message can include one or more items of location data. For example, the result message can include key-value pairs specifying geographic data, such as longitude, latitude, vertical accuracy, and horizontal accuracy. Further, the result message can include one or more items of time data. For example, the result message can include a time stamp indicating the time at which the location data was retrieved and a time stamp indicating the time at which the locate message was received. Accordingly, the accuracy of the location data can be at least partially assessed based on the reported time data.
FIG. 10 shows an exemplary user interface depicting the location reported by a mobile device in response to a locate command. The user interface 1000 can be configured for presentation on any display device, including a display associated with a mobile device. A map 1005 can be presented in the user interface 1000 , depicting a region that includes the location reported by the mobile device in response to a locate command. In some implementations, the map 1005 can be interactive and can include a resolution control 1008 for receiving input to increase or decrease the scale of the map 1005 .
The user interface 1000 also can include an address field 1010 that displays an address corresponding to the location reported by the mobile device. The address most closely corresponding to the reported location of the mobile device can be selected. For example, if the location reported by the mobile device is outside of an existing address, such as in a parking lot or greenbelt, the nearest available address to that location can be presented. A location indicator 1015 also can be presented on the map 1005 in the position corresponding to the location reported by the mobile device. Further, a legend 1020 can be displayed in conjunction with the location indictor 1015 . In some implementations, the legend 1020 can identify the mobile device reporting the displayed location. In some other implementations, the legend 1020 can indicate a geographic reference, such as the street address, location name, or geographic coordinates of the reported location.
FIG. 11 shows an exemplary user interface depicting an estimated location of a mobile device based on a response to a locate command. The user interface 1105 can be configured for presentation on any display device, including a display associated with a mobile device. A map 1110 can be presented in the user interface 1105 , depicting a region that includes the estimated location of the mobile device. In some implementations, the map 1110 can be interactive and can include a resolution control 1115 for receiving input to increase or decrease the scale of the map 1110 .
The user interface 1105 also can include an address field 1120 that displays an address corresponding to the estimated location of the mobile device. The address most closely corresponding to the estimated location of the mobile device can be selected. For example, if the estimated location is based on a Wi-Fi base station, the address associated with the Wi-Fi base station can be included in the address field 1120 . A location indicator 1125 also can be presented on the map 1110 . The location indicator 1125 can be centered on the estimated position, such as the location of the associated Wi-Fi base station. The location indicator 1125 also can be sized to approximate the area in which the mobile device can be located, such as in accordance with the approximate effective range of the associated Wi-Fi base station. Further, a legend 1130 can be displayed in conjunction with the location indictor 1125 . In some implementations, the legend 1130 can identify the mobile device reporting the estimated location. In some other implementations, the legend 1130 can indicate a geographic reference, such as an address, a location name, or the geographic coordinates corresponding to the estimated location.
FIG. 12 shows a mobile device displaying an exemplary message in response to a message command. The digital media player 125 includes a display 1205 , such as a touch screen. In response to receiving a remote command to display a message, the digital media player 125 can present a message window 1210 on the display 1205 . The message window 1210 can include a text message, such as contact information identifying the owner of the digital media player 125 . For example, the remote command sent to the digital media player 125 can include a text message, such as “If found, please call Jake at 866.555.1234.” In some implementations, the message window 1210 can include one or more images, graphics, effects, or links. The one or more images, graphics, effects, or links can be content transmitted in conjunction with the message command, content retrieved by the digital media player 125 , or content stored on the digital media player 125 . The message window 1210 can be presented using any arrangement of colors and fonts. Further, the message window 1210 can include an action button 1215 to permit closing the message window 1210 . In some implementations, the message window 1210 can be persistently displayed until the action button 1215 is actuated or other input canceling presentation of the message is received. Additionally, the message window 1210 can be displayed above any other screen content, such that it is viewable even if the mobile device is locked or displaying a screen saver.
FIGS. 13A and 13B show exemplary mobile device interfaces presented in response to an executed remote lock command. After a lock command has been executed by a mobile device, e.g. mobile telephone 120 , lock interface 1305 , shown in FIG. 13A , can be presented on an associated device display. When lock interface 1305 is presented, functionality associated with the mobile device can be inaccessible. In some implementations, one or more exceptions can exist through which functionality can remain accessible. For instance, an incoming telephone call can be answered even when the mobile device is locked. Also, a message can be presented on the device display and/or a sound can be output from a device speaker, such as in response to one or more mobile commands. Lock interface 1305 can include one or more graphical elements configured to permit unlocking the mobile device. For instance, slider 1310 can be manipulated, e.g. through a touch screen interface, to enter an unlock input that initiates unlocking of the mobile device.
FIG. 13B shows an example passcode entry interface 1315 , which can be presented on the mobile device display in response to received unlock input. Passcode entry interface 1315 can be configured to prompt a user to enter the passcode required to unlock the mobile device. In some implementations, passcode entry interface 1315 can include separate passcode entry boxes 1320 , such that an individual passcode entry box 1320 is presented for each character (e.g., letter, number, or symbol) included in the required passcode. In other implementations, passcode entry interface 1315 can include a single passcode entry box, which can be of any size, or no passcode entry box.
Further, passcode entry interface 1315 can include one or more character interfaces 1325 , which can be adapted to receive user input specifying a passcode. For instance, character interfaces 1325 can be arranged as a keypad in passcode entry interface 1315 , and can be actuated through corresponding input to a touch screen. Other configurations can be used in other interfaces. For instance, character interfaces also can be implemented as scrollable wheels, drop-down menus, or virtual keyboards. Additionally or alternatively, one or more physical controls included in the mobile device also can be used to enter one or more characters associated with a passcode.
FIG. 14 shows a flow diagram describing an exemplary process for processing a remote command message by a mobile device. Initially, a subscribed topic hosted on a notification service can be accessed, the subscribed topic corresponding to a mobile device ( 1405 ). A remote command message included in the subscribed topic that identifies a command to be executed by the mobile device can be retrieved ( 1410 ). Further, it can be determined whether the command can be executed by the mobile device ( 1415 ). Once it is determined that the command can be executed by the mobile device, a result message associated with the command can be published ( 1420 ). Further, the command can be executed by the mobile device based on the determining ( 1425 ). In some implementations, the result message can be published before, after, or in conjunction with execution of the command.
The techniques and functional operations described in this disclosure can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structural means described in this disclosure and structural equivalents thereof, or in combinations of them. The techniques can be implemented using one or more computer program products, e.g., machine-readable instructions tangibly stored on computer-readable media, for execution by, or to control the operation of one or more programmable processors or computers. Further, programmable processors and computers can be included in or packaged as mobile devices.
The processes and logic flows described in this disclosure can be performed by one or more programmable processors executing one or more instructions to receive, manipulate, and/or output data. The processes and logic flows also can be performed by programmable logic circuitry, including one or more FPGAs (field programmable gate array), PLDs (programmable logic devices), and/or ASICs (application-specific integrated circuit). General and/or special purpose processors, including processors of any kind of digital computer, can be used to execute computer programs and other programmed instructions stored in computer-readable media, including nonvolatile memory, such as read-only memory, volatile memory, such as random access memory, or both. Additionally, data and computer programs can be received from and transferred to one or more mass storage devices, including hard drives, flash drives, and optical storage devices. Further, general and special purpose computing devices and storage devices can be interconnected through communications networks. The communications networks can include wired and wireless infrastructure. The communications networks further can be public, private, or a combination thereof.
A number of implementations have been disclosed herein. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other implementations are within the scope of the following claims. | Methods, systems, and apparatus are presented for processing a remote lock command message. In one aspect, a method includes receiving, by a mobile device, a remote lock command message comprising a lock command and specifying a passcode to be set by the mobile device, locking the mobile device in response to the received remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and generating an acknowledgement message in response to the remote lock command message. Further, receiving the remote lock command message can include accessing a subscribed topic hosted on a notification service, the subscribed topic being associated with a lock command, and retrieving the remote lock command message from the subscribed topic. Additionally, locking the mobile device can include locking a display such that access to information stored on the mobile device and device functionality are blocked. | 7 |
TECHNICAL FIELD
Embodiments of the invention relate generally to decks and their construction methods. More particularly, the embodiments of the invention relate to a pool-covering deck apparatus and method of construction.
BACKGROUND
In the warmer climates, many homes are equipped with outdoor in-ground pools formed from shot-crete, (blown-in concrete) which is covered with a smooth water proof plaster. Such pools are often free form, such as the classic kidney shape, rather than the rectangular form preferred for exercise and competition. These swimming pools are usually surrounded by concrete decks which are level with the edge of the pools. In addition, many pools are equipped with a decorative ribbon of tile around the inside upper edge of the pool for easier cleaning, for a decorative effect, and because the tile does not deteriorate in the open hot air, whereas the plaster does.
Homeowners change their minds about the desire for a pool. Sometimes the children who used the pool have grown and no longer reside in the home. Other times, grandchildren appear on the scene and need to be protected from a swimming pool. New homeowners may purchase the home for its indoor characteristics and do not want the outdoor pool. The responsibility for the pool (problems of others gaining access and harming themselves) may weigh heavily on the homeowner.
Pool maintenance and upkeep include electricity to circulate the water and cleaning devices, chemicals to kill algae and maintain the proper salt balance and pH, water replacement, pool cleaning components such as hoses, pool maintenance charges by contractors, insurance arid pool replastering. Current estimates for pool maintenance and upkeep are estimated at about $2,000 per year. Closing off an unwanted pool can save the homeowner significant funds over a few years.
There are few alternatives for getting rid of the pool. For instance, pools can be filled in, often with the concrete deck that surrounded the pool, fill dirt, and then landscaped over. If the pool is filled in, it becomes difficult to be used again because it is extremely difficult to dig out the demolished concrete; replacing the pool is prohibitively expensive. A new pool often most be relocated to a less convenient part of the home's yard.
What is needed is a structure that can be individualized into the landscape plan without seriously damaging the swimming pool, which would permit the pool to he “revived” at a later date. Ideally such a structure would be added to completely cover the pool, preventing anyone, even small animals, front entering the pool. Preferably the structure would be attached to the pool so as to avoid damaging the expensive decorative tile ribbon around the top edge of the pool. Moreover, because concrete in-ground pools are built in a myriad of shapes and the structure covering the pool needs to be in a unique shape, there needs to be an efficient way to cut the wood deck planks to their proper size(s) and close tolerance with tire pool dimensions.
SUMMARY OF INVENTION
In one embodiment there is provided a deck that is level with the top of a concrete-sided pool having a decorative ribbon along the top of the pool side and a pool apron surrounding the pool having at least partially flat surface. The deck has a surface of decking surface members having lengths and ends, the lengths being sized to the dimensions of the pool and the surface being at the same level as the pool apron. Beneath the surface layer are support layers, including floor joists which are mostly perpendicular to the lengths of the decking surface members and underlying beams that form a sturdy base for the floor joists. The beams are supported by beam hangers secured to the sides of the pool below the decorative ribbon along the top of the pool side and being mechanically connected into the concrete side of the pool.
In another embodiment, there is provided a method of constructing an in-pool deck for use in covering concrete-sided pools. This method has the steps of a. affixing a plurality of beam hangers to the concrete side of the pool such that the bottom surface of the beam hanger is displaced a sufficient distance from the top of the pool surface to accommodate the height of the surface members, the floor joists, and the beam to be installed in the beam hanger; b. placing in each of the plurality of beam hangers at least one block and a beam, the block being used to position the deck structure above the pool surface; c. placing a plurality of floor joists at cross angles to the beams and affixing the floor joists to the beams; d. placing a plurality of deck surface members at cross angles to the beams and affixing the deck surface members to the floor joists to form a deck structure; e. drawing a saw along the deck surface members to cut off the excess lengths of the deck surface members and provide a deck surface which corresponds to the contour of the pool; f. placing a jack under the deck structure; g. raising the deck structure with the jack to permit the removal of at least one block in the beam hanger; and h. lowering the deck structure to permit the beams to rest in the beam hangers, thereby permitting the surface of the deck structure to become level with the top of the pool.
In another embodiment of the method, there is provided a step of arranging the floor joists at mostly right angles to the beams.
In another embodiment of the method, the step of placing a jack is performed after placing the beams, the floor joists or the deck surface members. Optionally, the method has the step of removing the jack. Optionally, the method has the step of placing a pump in the bottom of the pool. Optionally, the method has the step of creating an access door in the deck structure.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a deck being built to cover a swimming pool. Note that boards have been placed in the bottom of the pool for moving across the bottom of pool.
FIG. 2 is a perspective view of a swimming pool wall on which a beam hanger has been installed below the decorative stripe around the pool. The beam hanger contains a beam and blocks to shim the beam.
FIG. 3 is another perspective view of a swimming pool wall with decorative tile around its edge and beam hanger installed below the decorative tile and beams being installed
FIG. 4 is a perspective view of the deck being built to cover the swimming pool. In this view, floor joists have been added.
FIG. 5 is a perspective view showing the start of the deck surface with the placement of a deck surface member.
FIG. 6 is a perspective view of a partially built deck surface from which the excess lengths of board have been trimmed to fit into the free-form outline of the swimming pool.
FIG. 7 is a perspective view of the deck surface with access door. The excess board lengths have been trimmed from the deck surface.
FIG. 8 is an end view of the completed deck surface before it is lowered to the level of the concrete apron around the swimming pool.
FIG. 9 is a perspective view below the deck structure, showing a jack that is used to raise the deck structure sufficiently to remove the blocks under the beams. The blocks raised up the deck structure for rapid cutting of the deck surface members.
FIG. 10 is a perspective view of the finished deck structure with its deck surface flush with the surface of the pool apron. The access door is shown open to permit entry to below-deck where maintenance may be done on the pump.
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrating specific embodiments in which the invention may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of present inventions. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments of the invention is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
DETAILED DESCRIPTION OF INVENTION
The current invention incorporates unique features which offer important benefits appreciated by the owner of a pool. First of all, the deck is installed in a new configuration, such that the deck contact with the side of the pool is below the decorative tile rim around the pool. This gives the pool deck a semi-permanence, such that the structure can be removed at a later date, and the pool be returned to working status with a minimum of repair and cost. A pool is typically only replastered to the tile line. To replaster a pool the old plaster needs to be mostly chipped out with jack hammers, so none of the deck mounts are a detriment to the pool structure or repairs. All components used in the concrete walls can be replastered over without the problems of showing through or impeding the replaster process. Thus, replastering can be performed quickly. Were the deck structure installed in the usual manner (higher on the pool wall), the decorative tile rim would be damaged, requiring expensive replacement and delays in returning the pool to service. The decorative tile is saved from damage and not destroyed by drilling and mounting the beam hanger brackets around the upper perimeter of the pool. Instead, it is mounted just below the tile line to protect the tile from damage.
The structures described below can be assembled and installed for a modest investment, having a payback time of less than four years (taking into account the pool maintenance costs mentioned above).
The embodiments described below are built to normal building standards for floors and decks and usually far exceed structural requirements. In fact, most exceed commercial requirements for floor loading. If one desires to put even heavier loads on the deck, the deck can be easily reinforced for increased loads.
FIG. 1 shows an empty pool 10 in which several boards 12 a , 12 b , etc., or scaffolding, have been placed for workers to walk during construction. The scaffolding 12 a and 12 b are removed from the pool upon completion of the deck; alternately boards may be left in place to support stored items off the pool surface. Another advantage of the embodiments described below is that there is accessible space under the deck cover for storage of water-proof objects, such as kayaks, old pool equipment, plastic storage boxes, etc.
FIGS. 2 and 3 show the locations of anchors and beam hangers 40 being placed into the pool side. Note that the beam hanger 40 location is below the decorative tile rim 30 , or at least it is not fastened into the tile of the pool. The beams 50 are placed in these beam hangers 40 and form the base for the pool structure. The beams 50 are shimmed up with blocks 60 a , 60 b , to raise the deck structure above the concrete apron 20 . The blocks 60 a , 60 b , etc, are removed when deck structure (see below) is completed and lowered to concrete apron 20 level.
FIG. 4 shows the beams 50 in place. Their locations are selected based on the lengths of the floor joists 70 they bear. The horizontal beam 50 placement and distances between adjacent beams 50 are determined by well known calculations used in conventional floor and deck design. FIG. 4 also shows some of the floor joists 70 in place in the emerging deck structure. These floor joists 70 extend across the pool. Their depth is chosen based on conventional deck design in consideration of the weight of deck surface members 80 (discussed below) and other weight they are intended to support. To accommodate greater weights, the beams may be taller or closer together and the floor joists also can be taller or closer together, and other vertical support from the bottom up to the beams may be added. The floor joists 70 are placed over the beams 50 at mostly perpendicular angle(s) to the beams. Mostly perpendicular angles range from approximately 60-120°, preferably 75-105°, and most preferably 80-100°; of course, the joists 70 can be installed at perpendicular angles to the beams 50 .
FIG. 5 shows a deck surface member 80 placed on the floor joists 70 to which it will be affixed with nails, screws or other such fasteners. FIG. 6 shows numerous deck surface members 80 on the floor joists 70 . In this embodiment, the deck surface members 80 are initially positioned above the concrete apron 20 . At this height, it is easier to cut deck members 80 to accommodate the pool's outline. The deck surface member 80 is placed over the joists 70 at mostly perpendicular angle(s) to the joists 70 . Mostly perpendicular angles range from approximately 60-120°, preferably 75-105°, and most preferably 80-100°; of course, the deck surface member 80 can be installed at perpendicular angles to the joists 70 . In this embodiment, the deck surface member 80 is a plank.
FIG. 6 shows a partially built deck surface from which the excess lengths of deck surface members 80 have been trimmed.
FIG. 7 shows an access door 90 to the area underneath the pool deck. This enables access to the under-deck area for performing final steps of construction and allows access to maintenance of motor pump (not shown) that is required to keep pool empty of water. The access door also allows entry of items to be stored, such as pool mechanicals, other outdoor equipment or water proof containers.
FIG. 8 is a side view of a completed deck 100 , which is raised above concrete apron 20 . In this embodiment, with the deck surface raised above the surrounding pool deck, the ends of the deck surface members 80 are sawed off in a continuous motion around. Such a cutting method permits the carpenter to blend the edges of adjacent members.
FIG. 9 provides a view under the deck structure 100 accessed through door 90 . A jack 110 has been placed to raise deck structure 100 a few inches to take pressure off the beams 50 and allow removal of blocks 60 a , 60 b , shown in FIG. 2 . Jack 110 then is used to lower the deck structure 100 level to that of the concrete apron 20 .
FIG. 10 shows a completed deck surface 100 flush with the surrounding concrete apron 20 . Also shown are the access door 90 and a pump 120 . Through the access door 90 , the pump 120 is lowered and placed at the lowest point of the pool to pump out water from rain or other sources.
EXAMPLE 2
In this embodiment, a deck structure 100 is constructed as described above, including installing the beam hangers 40 below the decorative tile rim 30 of the pool. However, in this embodiment the beams 50 are placed directly into the hangers without the use of shimming blocks 60 . The rest of the beams 50 are so installed. The floor joists 70 are installed the same. However, each deck surface member 80 is individually placed after it has been sized and sawed to the precise length needed at its location on the deck.
When deck members were individually sized and then attached to the deck, these steps took approximately 3 days for a free-form pool measuring at the maximums 20 feet by 40 feet. When the new pool construction method (using shims and jacks to raise the structure) was invented and used, the construction time decreased to a little over one day. Not only was the time savings huge, but the overall appearance of the deck edge improved. Because the sizing of all the deck members was performed in a smooth, continuous motion, the adjacent deck members had more consistent and attractive blending of edge lines.
Decks are made from treated lumber, composite material. Aluminum, Western red cedar, teak, mahogany, and other hardwoods and recycled planks made from high-density polyethylene (HDPE), polystyrene (PS) and PET plastic as well as mixed plastics and wood fiber (often called “composite” lumber).
A variety of braces, brackets and hangers can be used to support and form the deck structure. For example, the bracket that is anchored to the pool wall can be a conventional beam hanger or other conventional bracket used in the industry.
Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve the same purpose can be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention. It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description. The scope of various embodiments of the invention includes any other applications in which the above structures and methods are used. Therefore, the scope of various embodiments of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.
It is emphasized that the Abstract is provided to comply with 37 C.F.R § 1.72(b) requiring an Abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Description of Embodiments of the Invention, with each claim standing on its own as a separate preferred embodiment. | A deck is disclosed that is level with the top of a concrete/plaster pool having a decorative ribbon of tile along the top of the pool side and an apron surrounding the pool having at least a partially flat surface. The deck has a surface of deck surface members having lengths and ends, the lengths being sized to the dimensions of the pool and the surface being at the same level as the pool apron. Under the deck are supports of joists which are mostly perpendicular to the decking surface members, of underlying beams that form a sturdy base for the joists and beam hangers being secured to the sides of the pool below the decorative ribbon along the top of the pool side and being anchored into the concrete side of the pool. Also disclosed is an improved method for installing such a deck. | 4 |
SUMMARY OF THE INVENTION
The invention relates to an automatically controlled low-pressure casting process which is characterized by the following:
(a) In a casting station, the first of a number of casting molds (arranged at regular distances on a revolving table) is disposed at a known type of low-pressure furnace where it is filled with molten metal through the ascending pipe of the furnace. At the same time a second opened mold is submerged automatically at an immersion station in a treatment bath and is raised therefrom. Again at the same time, a third partially opened mold is prepared at a preparation station to perform the casting step at the next station which is the casting station. For example, cores may be inserted in the mold during this step.
(b) After the function of each station is performed the molds are revolved together on a revolving path until each reaches the next station where the various functions are repeated. However, the mold with the casting therein is automatically opened and emptied, after leaving the casting station and before reaching the immersion station, at a mold removal station. The mold upon leaving the treatment bath is tipped or tilted into a horizontal position. Each mold, after having been closed and prepared for the casting, is swung into a vertical position and lowered upon the furnace nozzle to receive molten metal.
(c) It is advantageous for the circular motion of all molds to be interrupted, as each mold, in turn, reaches the casting removal station whereby the immersion and preparation steps occur at the same time as the casting step.
(d) For the automatic removal of the cast pieces from the mold and to avoid injuring or otherwise blemishing the castings, opened molds are vibrated sufficiently to effect removal of the casting at the mold removal station.
The invention also relates to a mechanism for executing the above-described process characterized by revolving table which has arranged on its periphery at equal degrees of arc a number of similar (or in some cases different) casting molds supported by movable, turnable and extensible carrying devices for automatically opening and closing, tipping, raising and lowering the mold parts. Around the turntable, there are arranged a casting station with a known low-pressure furnace having an ascending pipe and furnace nozzle, an immersion station with a mold treatment bath, and a casting preparation station, as well as a casting removal station disposed between the furnace and the immersion bath. A driving gear or other appropriate driving device moves the molds from station to station and a control system is provided for automatically carrying out the various functions.
For adaptation to the automatic mode of operations, a known low-pressure casting furnace is preferably provided which includes a syphon-like filling chamber, the connection of which is, in the furnace's proportioning chamber, below the lowest surface level of the molten metal. By this means, an outflow of protective gas used as the pressure medium for casting is precluded during refilling the furnace with molten metal.
An important object of the invention is to provide an arrangement with an operational adaptability whereby automatic known manual casting processes can be performed completely or at least substantially, automatically, in a mechanism involving a series of casting molds arranged on a rotary casting machine which are filled one after the other with molten metal. Thus manual operations may be limited to tasks such as inserting mold cores, starting and stopping the mechanism and monitoring the mechanism's various evolutions.
For the filling molds moved on a circular path, a known low-pressure casting furnace (DEPS No. 2041588, DE-OS No. 2128425) is utilized with modifications adapted primarily for the automatic functioning of the invention.
Advantages of the invention involve not only the reduction of operational personnel, although in any event one person is still required for inserting cores and monitoring the installations, but also in the fact many manual operations may be eliminated which, in the conventional manual casting processes with rotary casting machines, were physically taxing, disagreeable and frequently dangerous, such as the manual handling of containers of the molten metal as well as annoyances of the accompanying noise, heat and gaseous emissions. Thus, the invention improves working conditions and environment substantially.
Further, the adaptation of the low-pressure casting process to automatic operations provides advantages in the control of filling molds, control of the casting to ensure adequate solidification, minimizing unneeded melting of the molten metal, reducing the time and expense required for melting the metal, improving the castings' quality, reducing foam or scum formation, minimizing risks of losing the protective gas atmosphere, and economizing the amount of metal invested in the inlet and delivery system.
Other objects, adaptabilities and capabilities of the invention will be appreciated by those skilled in the art as the description progresses, reference being had to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are simplified sectional views of the casting station of a device according to the invention with a low-pressure casting furnace and a mold on its outlet pipe;
FIG. 3 is a plan view of a device according to the invention illustrating the arrangement of the casting mold removal, immersion and preparation stations;
FIG. 4 is a sectional view corresponding to FIGS. 1 and 2 in somewhat larger scale with more details;
FIG. 5 is a sectional view taken on line V--V of FIG. 4;
FIG. 6 is a sectional view taken on line VI--VI in FIG. 4;
FIG. 7 is a plan view of the furnace of FIG. 4 with a multiple nozzle;
FIG. 8 illustrates in partial section the arrangement of molds in the casting position;
FIG. 9 is a plan view of the arrangement shown in FIG. 8;
FIG. 10 corresponding to FIG. 8, illustrating the mold opened for ejection of a cast part;
FIG. 11 is a side elevation of mold in the immersion position similar to FIG. 10 in an enlarged scale;
FIG. 12 is a plan view of the immersion station;
FIG. 13 illustrates molds corresponding to FIGS. 8 and 10 in the preparation station; and
FIG. 14 is a plan view of the preparation station.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the Figures, an ingot mold 1, consisting of two halves 1a and 1b, is located in casting station G and in the closed vertical position, it is lowered onto the furnace nozzle of a low-pressure casting furnace 2. The latter is filled with molten metal 3 and includes, disposed above the molten metal surface 4, a cylindrical proportioning chamber 5 filled with a protective gas, for example, nitrogen.
By raising the pressure of the gas in chamber 5, mold 1 operates or causes molten metal surface 4 to lower and molten metal 3 to rise slowly through an ascending pipe 6 to a furnace nozzle 7 which can be one of several known nozzles, including a multiple nozzle, as required for the pieces to be cast in space 8. The parameters of casting speed and casting time for a bubble-free casting can, within the limitations of automatic control, be programmed for different molds by well-known techniques. Molten metal is thus introduced from pipe 6, through nozzle 7 into mold 8.
After expiration of the time required for solidification, the gas pressure in chamber 5 is reduced and the unsolidified metal in furnace nozzle 7 drops or falls into pipe 6 while at the same time molten metal surface 4 rises in chamber 5. Preferably, any protective gas removed from chamber 5 during this step is drawn without loss into a special container (not shown) for this purpose. When casting has been completed, mold 1 is automatically raised from furnace 2.
Preferably, the low pressure casting furnace 2 is an induction channel-type furnace with a melting or molten metal channel 9, a coil 10 and iron yoke 11. The smelting or melting space of furnace 2 is formed by proportioning chamber 5 above channel 9.
To maintain molten metal surface 4 at each casting at the same level and thus balance the metal used in the casting process, a displacement body 12 is provided, which is controlled by a rod 13 received in cylinder 14. The amount of displacement of body 12 in the molten metal 3 is controlled automatically in dependence on the volume of the cast piece.
After a certain number of castings, displacement body 12 reaches a predetermined lowest position which causes actuation of a signal which informs an operator that refilling of casting furnace 2 is required and, at the same time, causes displacement body 12 to return to its uppermost position. Furnace 2 is filled with fluid through a chamber 15 which has a connection 16 with proportioning chamber 5 which is below the lowest level 17 of molten metal 3. This prevents protective gas from escaping from proportioning chamber 5. Molten metal is introduced through chamber 15 until molten metal surface 4 reaches a height near and preferably under displacement body 12 in its highest position.
During the above-mentioned casting process, a second opened mold 1' is in at immersion station T, such mold having been lowered into a position as seen in FIG. 11 from a raised position represented in FIG. 10. Mold 1' is thus submerged in a treatment bath 20 contained in basin 19.
Bath 20, for example, a finishing or lubrication bath, is normally equipped with an agitator and preheated through a heating cartridge therein (neither being shown). The depth of the mold's submersion as well as its timing are preprogrammed, depending on the size of the mold so the temperature of the mold remains constant. Thereafter the mold is returned to the position shown in FIG. 10.
A third mold 1" is, during the above-mentioned process, in a preparation station V in the partially opened position seen in FIG. 13, where an attendant monitors the automatic operational processes, cleans out the mold with compressed air as required, and inserts mold cores insofar as these steps are not performed automatically.
After completion of the third of the above-mentioned processes, which is of longest duration at which time the revolving table 21 carrying the molds is stopped, revolving table 21 is turned in the direction of arrow A and with it molds 1, 1' and 1" are moved in a circular path until those following the three above-mentioned ingot molds have arrived in the described stations upon which the process is repeated.
After leaving casting station G, mold 1 is opened and its casting is dislodged therefrom at separation station E before reaching immersion station T (FIG. 3). At station E, mold 1 is placed in the separated disposition shown in FIG. 10. Mold 1' leaves the finishing or lubrication bath and is brought, half-opened, into the horizontal position during this movement on a circular path as seen in FIG. 13, while the third mold 1" is closed, disposed vertically, and lowered, upon reaching casting station G, onto nozzle 7.
To avoid marks or blemishes on the upper surfaces of finished cast pieces, which for example, are produced by conventional ejector pins, the ejection of the cast pieces from the molds is caused by subjecting the opened ingot mold at mold separation station E to vibration. For this purpose, a compressed air vibrator 22 is provided on clamping plates 23 (FIG. 11), on which mold halves 1a and 1b are fastened by bolts or other suitable fastening means.
The cast pieces removed from the molds fall onto a conveyor belt 24 (FIG. 3). Conveyor belt 24 moves the cast pieces along a cooling line in the direction of an intercepting container. It is controlled to be switched automatically after ejection of each cast piece and the cast pieces are conveyed in a timed manner to the intercepting container. In this connection, the conveying process is preferably adjustable to operational conditions selectively to control the period of cooling and to provide an attendant the capability of controlling the speed and direction of conveyor belt 24.
To ensure castings are dislodged onto conveyor belt 24 it frequently is desirable to stop the molds for a short period at station E and there is thus an advantage to providing equal arcs of movement of turntable 21 between stations E, T, V and G of 90° than simply between stations G, T and V of 120°, as shown in FIG. 3.
Where a longer solidification time after casting, in the closed mold 1, is desired, the arc of movement between stations G and E may be increased whereby station E is nearer station T.
Five or seven molds, or a multiple thereof, may be employed whereby the cooling of the coating while in the mold may be prolonged through several "station stops." On the other hand, it is conceivable to use only two ingot molds, placed diametrically opposite each other, especially if stopping of the turntable in neither in preparation station V nor mold removal station E is required or the period the table is stopped in these stations is extraordinarily short.
If desired, automatic control of the process may be programmed to end when a selected ingot mold arrives in the preparation station where it must be started again by the attendant. Alternatively, it can be programmed to operate, after starting, in a fully automatic fashion with pre-programmed stoppages in the above-mentioned stations until interrupted by the attendant or automatically because of an interruption instruction.
As should be readily understood from the above description of the device's operations, individual molds carry out opening, closing, tipping or tilting as well as raising and lowering motions, which are obtainable by electrically or electronically programmed pneumatic or hydraulic systems. The technical specifics of such controls are not objects of the present invention and are well within the skill of those who practice the various arts involved. Nevertheless, the above-mentioned operations are accomplished through the following described arrangements with particular reference to FIGS. 11, 12 and 14.
As previously described, both mold halves 1a and 1b are fastened to clamping plates 23 onto which the above-described compressed air vibrator 22 is also secured. Clamping plates 23 are connected by bars 25 to closing plates 26 which, with the assistance of pins 27, are pivotally connected to bearing plates 28.
Closing cylinders 29 are also connected to bearing plates 28 whereby they are movable in swing bearings or trunnions 30. The ends of piston rods 31 received in cylinders 29 are journalled by pins 32 to closing plates 26. The outward motion of piston rods 31 of closing cylinders 29 causes an arcuate movement of closing plates 26, and therewith of mold halves 1a and 1b, around pins 27 to the opened position represented in FIGS. 10 and 11, whereas inward motion of piston rods 31 causes a return arcuate movement of mold halves 1a and 1b back to into the closed position represented in FIG. 8. In FIG. 13, it will be noted piston rod 31 of the piston and cylinder assembly 29 has its piston withdrawn into the lower closing cylinder 29 and piston rod 31 is extended from the upper closing cylinder 29. Thus, in this Figure, one mold half, 1a, is in its closed position and the other mold half 1b in its opened position.
Although the above described arcuate motion of mold halves 1a and 1b is sufficient to open and to close mold 1, and thus permit the steps of casting, mold removal, and immersion (with a subsequently later described lowering motion) it is especially advantageous that at preparation station V shown in FIGS. 13 and 14, the mold halves 1a and 1b can be controlled independently and placed in the separated relationship illustrated in FIG. 13. For this purpose each bearing plate 28 has connected thereto a support plate 33 and 34, respectively, arranged one to each mold half 1a and 1b. Plates 33 and 34 are connected with each other through a pair of telescoping cylinders 35 by which plates 33 and 34 and with them the closure system of the mold halves 1a and 1b can be moved together and apart.
As previously set forth, it is necessary for placing the molds on furnace nozzles 7 as well as for their immersion into the treatment bath to provide the capacity to raise or lower such molds. For this purpose, support plate 33 is connected to frame parts 36 and 37, which by means of frame parts 38 connects with angle plates 39. The lower ends of guide cross beams 40 are, in turn, connected with angle plates 39. The outer ends of piston rods 41 bear upon angle plates 39, such rods extending from hydraulic lowering cylinders 42 which are fastened on brackets 42 which project from guidance blocks 44 which receive and guide cross beams 40. An outward motion of the piston rods 41 thus causes the lowering of angle plates 39 and of cross beams 40, which are guided by guidance blocks 44. This motion causes, via angle plates 39 and frame parts 36, 37 and 38, the lowering of support plate 33 and mold half 1a connected with it. At the same time, support plate 34, carried by telescoping cylinders 35, and mold half 1b connected thereto, are similarly lowered.
Bearing pins 45 pivotally connect guidance blocks 44 to supports 46 and 47 whereby blocks 44 together with beams 40 and the above-described system may be tilted from the vertical into the horizontal position as represented in FIGS. 13 and 14. To accomplish this, a swinging cylinder and piston assembly 48 and 50 has its cylinder's outer end fastened by a pin 49 to support 46 while its piston rod 50 is adapted to move in an arc, through a pin 51, a swinging plate 52 which is rigidly connected with one of the guidance blocks 44. Supports 46 and 47 are firmly secured to revolving table 21 by means of bolts 53.
Control of the above-mentioned working or operational cylinders results, as alredy indicated, from pneumatic or hydraulic systems through valves controlled by electrical or electronic arrangements well within the skill of the art.
A casting mechanism in accordance with the foregoing description is capable of producing up to 180 castings per hour per mold. It has been found that the average mold insertion time is approximately ten seconds, the average casting and solidification period is also approximately 10 seconds and the circuit time for each of the three mold stations is approximately 10 to 13 seconds for each casting operation. Thus, with three molds in the mechanism, a casting cycle of about 20 to 23 seconds is possible which provides the maximum output of up to about 540 castings per hour. The type of furnace used in practice has a capacity of about 600 kilograms. Brass is a typical metal used in the type of furnace involved.
The drawings, although simplified and not exactly to dimension, nevertheless disclose the general relationship of the various components of the invention. The turntable or carousel is preferably driven by a gear arrangement and its various starts and stops as well as other operations are easily achieved through timed rotation of switch contacts as found on many types of apparatus to control sequential processes such as, for example, household washers and dryers. Digital and other types of programming is also possible and it is considered that a detailed disclosure of this aspect of the mechanism is so well understood that its specific disclosure herein would only serve to lengthen and confuse to a certain degree the specification in an undue manner.
It will also be appreciated that although preferred embodiments of the invention are described above, the invention is capable of other adaptations and modifications within the scope of the following claims. | A low pressure casting process using a furnace of the channel-type induction for heating, the furnace power being automatically controlled by direct temperature measuring of the molten metal bath according to the desired casting temperature. The feeding chamber of the furnace is of pressure-type and has a protective gas with a slight over-pressure. The furnace is filled via a syphon-shaped feeding chamber whereby metal is inserted below the level of molten metal in the feeding chamber and the protective gas therein is not affected. An operator starts the casting process whereby a casting mold is closed and assumes a casting position over the casting nozzle from the furnace and metal is forced into the mold. The mold, one of several on a carousel is moved to a station wherein the casting is automatically discharged to a conveyor belt. The mold next moves to an immersion bath where it is treated, and then to a preparation station wherein it may be cleaned and cores inserted. Finally, the mold returns to the casting station. Three such molds are shown which rotate simultaneously about a common axis of the carousel. The support for each mold permits the opening of the mold into mold halves for the immersion station and the tilting of the mold for the preparation station. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of plastic fabrication and uses. More specifically, the present invention relates to multilayered plastic films that have antifogging and antimicrobial properties.
BACKGROUND
[0002] It is known that many thermoplastic polymer packaging materials, such as films, coatings, sheets, bags, and the like, with suitable strength and flexibility are used to enclose perishable foods, fruits, raw meats, daily dishes and vegetables. These packaging materials tend to discolor and fog during extended storage. Because of this, polymer packaging materials have to possess the following characteristics: (1) suitable thickness and cohesive properties for packaging, (2) high antifogging properties, i.e. the films do not accumulate water droplets on the surface of the material, (3) high mechanical strength at break, (4) appropriate slip properties, (5) excellent optical characteristics, such as gloss and transparency, and (6) sealability under heat.
[0003] There is a high demand in the packaging food industry, agriculture, industrial markets, flower wrapping trade, and the like for biaxially oriented thin antifogging films of different types that can be used for both food-wrapping and agricultural applications. The antifogging and antimicrobial films reduce the growth of living contaminants (such as bacteria and molds) and ensure that any condensation of water vapor occurs as an uniform, invisible, layer of water rather than as a series of individual droplets which are not only aesthetically undesirable but produce damaging effects.
[0004] The several goals of these films are: (1) to ensure that the polymer thin films retain their transparency so that the packaged contents are clearly visible and so that there is maximum light transmission into the enclosure, (2) to protect the packaged food products from undesired degradation that may be caused by the droplets of water, (3) to prevent large drops of condensed water from falling onto young plants, increasing the possibility of damage and disease, (4) to prevent plant “burning” caused by large drops of water lensing (concentrating and focusing) solar radiation onto the contents of the package, (5) to provide antimicrobial properties and (6) to provide prolonged shelf life by preventing the growth of the certain bacteria.
[0005] Currently, antifogging films (also known as antifog or antimist films) are produced by adding or coating various types of organic antifogging additives, such as ethoxylated sorbitan ester, glyceride fatty acid ester, glycerol stearate (or monostearate), glycerol oleate and sorbitan ester, and the like, to conventional film forming polymers, such as polyolefins, flexible vinyl chloride polymers, oriented styrene polymers, polyesters, ethylene-vinyl acetate copolymers, and the like.
[0006] There are a number of available patent publications related to antifogging polymer films obtained by using different types of thermoplastic film-forming/antifogging additives as discussed below. These patents relate to systems such as a biaxially stretched film with a base of an olefin polymer resin composition containing ethylene-propylene copolymer and 0.5% of polyethylene glycol stearyl ether, olefin polymer/fatty acid monoester of polyhydric alcohol (or alkaline metal salt of a diester of sulfosuccinic acid), polyolefin/ethylene oxide (or monoglyceride of a fatty acid), polystyrene/alkyl phenyl polyethylene glycol ether (of fatty alcohol sulfate) base coating, polyethylene/polyhydric alcohol esters or metal salts of either saturated or unsaturated monocarboxylic fatty acids, ethylene polymer and polybutene blend/glyceride with acyl group, and ethylene-acrylic acid (or ethyl acrylate and/or vinyl acetate) copolymers or low density ethylene polymers/alkyl phenyl polyethylene glycol ethers or alkoxylated alkyl phenol. But all of these patents suffer from one or more of the following disadvantages such as higher haze values, low values of sheen, higher transverse or longitudinal shrinkage, and poor antifogging properties.
[0007] More specifically, in U.S. Pat. No. 4,066,811, there is disclosed raw tubular polyolefin films with suitable orientation determined by heat shrinkage, containing ethylene-vinyl acetate copolymer, polyethylene, polypropylene or mixtures thereof, polyalkylene ether polyol and non-ionic surfactant-polyhydric alcohol ester derivatives of fatty acids. In the above patent, the determination of antifogging properties of the subject film was according to the following measurements: (1) no water droplets were present on the surface and water was in a uniform layer, (2) large water droplets locally were adhered or there was unevenness in the state of any adhering water droplets, and (3) fine water droplets adhered to the whole surface.
[0008] Other recently published patented inventions, such as JP Pat. 09-104,092, relate to various polymer compositions, sheets, and films having fog resistant properties. Disclosed therein are antifogging sheets comprising weather-resistant polycarbonate based films, hot-melt poly(methylmethacrylate) films containing a benzotriazol UV-absorber, and cellulose films containing a diethyl phthalate plasticizer, to form a flat or wavy laminated panel allegedly providing good weather and moisture resistant adhesion.
[0009] Antifogging polypropylene lids with smooth handling properties, such as disclosed in JP Pat. 09-76,339, were prepared by thermal formation of polypropylene sheets, where the interior faces of the lids exhibit antifogging property and the exterior faces have a friction coefficient of 0.01-0.7. The plastic of these lids was stretched in the machine direction, coated on the exterior face with poly(dimethylsiloxane) and on the interior face with sugar fatty ester emulsion, and thermal formed into a lid showing no noise when removed from their stack.
[0010] Plastic sheets having anisotropic surface characteristics, including fogging and adhesion properties, are disclosed in JP Pat. 09-85,847 and comprise alternating strips of nylon 6-12 and ethylene-methacrylic acid copolymer.
[0011] There are antifogging laminated films for agricultural uses that use a polyolefin resin middle layer. This layer frequently consists of high density polyethylene and synthetic rubber with external layers consisting of antifogging agents. One laminate, disclosed in JP Pat. 0994,930, comprises an ethylene-vinyl acetate copolymer middle layer, uses KFG 561 as an antifogging agent, and showed good blocking resistance, mechanical strength and fogging presentation (45° C. water for 45 days or 0° C. environment and 20° C. water for 24 hours).
[0012] Other agricultural antifogging films, such as the ones disclosed in JP Pat. 09-95,545, were prepared using olefin copolymer compositions containing sulfonated olefin copolymers, ethylene-C 3-12 olefins, and ethylene-acrylic copolymers. The olefin copolymers were synthesized by polymerization of olefins in the presence of metallocene (Zr) catalyst containing silica and methylaluminoxane. More specifically, a transparent antifogging film was prepared from a mixture of 80% sulfonated olefin polymer (reaction product of butane sulfonate with ethylene-acrylic copolymer) and 20% of ethylene-hexene-1 copolymer which was polymerized in the presence of a catalyst system containing silica, methylaluminoxane, bis(1,3-n-butylmethyl cyclopentadienyl)zirconium dichloride and triisobutylaluminum.
[0013] JP Pat. 09-77,938 discloses a polymer composition with good sliding properties that comprises 10-60% of graft copolymers manufactured by grafting an elastomer with ≧1 layers of antifogging agent KFG 561. The resultant laminate used ethylene-vinyl alcohol copolymer as a middle layer, 20% of hydrogenated butadiene-styrene elastomer as an inner layer, and 10% of the said elastomer outer layer comprises a fire retardant agent and showed good blocking resistance, mechanical properties, dust, and fogging presentation.
[0014] Fluoropolymer films with wetting ≧35 dyn cm, as disclosed in JP Pat. 09-136,980, were mixed with antifogging agents comprising water-thinned acrylic polymer emulsions, such as ethyl acrylate-2-hydroxyethylmethacrylate-2-hydroxymethacryloxybenzophonone-methyl methacrylate copolymer, and colloidal SiO 2 . Films prepared according to this patent showed reasonably good antifogging property for 7 months.
[0015] Two Japanese patent inventions, JP Pat. 09-165,178 and JP Pat. 09-165,447, disclose heat-aging and light-resistant propylene polymer compositions causing no fogging of glass for use in automotive interiors. These compositions contain (A) crystalline polypropylene, (B) inorganic filler, such as TiO 2 , (C) ethylene-propylene elastomer, and (D) conventional stabilizers, antioxidants, antiblocking agents, and other additives such as epoxy resins, hydroxyl-containing low molecular weight polyolefins, polyethylene waxes, and anionic surfactants. Plates prepared from this composition by kneading, pelleting, and injection molding show 150° C. oven life for 320 hours. The plate and glass plate were left in a sealed container at 120° C. for 20 hours and showed a haze of the glass of 0.8%.
[0016] In another patent entitled “Fog-Resistant Heat-sealable Film”, U.S. Pat. No. 4,341,825, there is disclosed a transparent, heat-sealable, laminated film that has a first layer of a difficulty heat-sealable polymer, such as an axially oriented polyethylene terephthalate film with 0.002-0.006 cm thickness, and a second layer of a readily heat-sealable polymer, such as low density polyethylene and copolymers of ethylene with acrylic acid, ethyl acrylate and vinyl acetate, chemically interfacially joined to the first film layer. The said second film layer comprises 0.2-0.7% of an alkyl phenyl polyethylene glycol ether of the formula, R—C 6 H 4 —O—(CH 2 ) n OR′—OH, where R-alkyl C 10-15 and alkylene C 4-10 as an antifogging agent. The resulting laminated film is then heated to 130° C. and exposed to UV-light through the second film layer for a time and at an intensity sufficient to cause the formulation of the chemically interfacial bond between the two layers. The film obtained resists the formation of fog when utilized to package refrigerated foods. However, the disadvantages of this invention can be noted as the following: (1) the subject film comprises two layers containing non-oriented ethylene polymers, (2) the subject film has a high thickness, (3) the subject film has a high content of antifogging agents as compared with more conventional polymer fog-resistant films, and (4) the antifogging agents used in the subject film were synthesized by reaction of alkyl phenol with polyethylene oxides. In this case, the trace of the phenol will be present in the product synthesized. This can limit the use of this specific additive in the food packaging industry.
[0017] Another patent, entitled “Fog-Resistant Olefin Polymer Films”, U.S. Pat. No. 4,486,552, discloses a film-forming composition for making packaging films that are resistant to fogging, especially when employed as a packaging film for moist products. The subject film of this patent comprises an ethylene polymer, especially a linear low density polyethylene, and 0.5-2.0% of antifogging agents, such as an ethoxylated alkyl phenol along with a mixed mono-, di-, and/or triglyceride, a polyoxyalkylene fatty acid ester or various combinations of said additives. The mixing of the antifogging agents into the ethylene polymers, which can be LDPE, LLDPE, HDPE, ethylene-octene-1, or blends or alloys of said olefin polymers, is done by mixing the antifogging agents into molten polymer by commonly used techniques, such as roll-milling, mixing in a Banbury type mixer, mixing in an extruder barrel, or the like. The subject film was formulated as 0.015 mm on a cast film unit at 260° C. melt temperature and chill roll temperature of 18° C. It is noted that the films prepared according to this patent have a relatively high fog resistance when compared with commercially available plasticized poly(vinyl chloride) films, such as the one disclosed in U.S. Pat. No. 4,072,790. Further, other high qualities are produced, such as improved transparency (64.3 against 5.0 for PVC), gloss (95.9 against 89.0), haze (1.0% against 2.0%), lower heat seal range (121-127° C. against 149-177° C.), and overall toughness, as compared to PVC films. However, it was shown that the antifogging agents used in this patent exude to the surface of the film within approximately 48 hours after fabrication. The subject films of this patent have the following disadvantages: (1) the films are not multi-layered and biaxially oriented, (2) the films have a high thickness and high density resulting in a low yield, (3) there is a low heat-sealing temperature, (4) there are low values of surface and mechanical characteristics, the film surfaces are not treated by corona discharge, and (5) the film comprises relatively high concentrations of antifogging agents used in the polymer composition.
[0018] U.S. Pat. No. 4,876,146 and 4,956,209, disclose “Anti-fogging Multi-layered Film and Bag Produced Therefrom for Packaging Vegetables and Fruits”. These patents describe biaxially oriented and multilayered antifogging polyolefin films useful for packaging fresh vegetables and fruits comprising: (A) a 4-100 μm base layer formed from polypropylene or ethylene-(5%)-propylene popolymer or ethylene-vinyl acetate (acrylic acid or styrene) copolymer; and (B) one or two surface layers that are 0.3-8.0 μm thick and having heat-sealable properties resulting from a (1:1) mixture of propylene-butene-1 (18%) and ethylene (3.5%)-butene-1 copolymers containing 0.3-3.0% antifogging agent such as higher fatty acid ester of monoglyceride (or alkyldialcoholoamide, polyalkylene glycol, polyalkylene glycol alkylphenol ether). There are also other conventional additives, such as antistatic and lubricating agents. In accordance with said patent it is possible to incorporate the antifogging agent only in a base layer of the film so that the antifogging agent migrates to and diffuses into the surface layer(s) after laminating the layers. This migration and incorporation of the antifogging agents into the surface layers provides the antifogging property important to the surface layer. Antifogging properties were observed, the film was formed as a bag and “Shtitake” mushroom were enclosed in the bag; the temperature was varied twice per day with a rise and drop between 20 and 40° C.; the result was observed after 1 day. There was little fogging, discoloration, and the measured surface tensions were 38-42 dyne/cm. The disadvantages of the films prepared in accordance with said patent included: (1) high values of haze (3.1%), (2) low values of sheen (86.6%), (3) coloring agent in the film does not comply with food contact standards of the U.S. FDA, (4) the identification of fogging properties used a non-effective method, (5) the films had low performances as antifogging surfaces, i.e. discontinuous film of water is observed on the surface, (6) E-P-B terpolymer is not used in the surface layers, (7) ethylene-vinyl acetate copolymers are used in the base layer and most probably for improvement of barrier properties of films, and (8) present patent is limited to using 2-3 layered films. U.S. Pat. No. 4,876,146 and 4,956,209 which are hereby incorporated by reference.
[0019] All of the patents previously mentioned above, however, suffer from not having antimicrobial properties.
[0020] In the recent years, essentially growing trend is the use of various bioactive agents, including predominantly ecologically pure metal-containing biocides in polymer production industries for preparation of antimicrobial, antibacterial and antifungal polymer materials such as films, sheets, coatings, plastics, fibers, composits, etc. The number of patent publications in this field have increased in recent years. The following references have attempted to address antimicrobial films: (1) U.S. Pat. No. 4,938,955, 1990 discloses an antibiotic resin composition comprising at least one antibiotic zeolite of which ion-exchangable ions are partially or completely replaced with ammonium ions (5-15%) and antibiotic metal ions (Ag + of 1-15%), at least one discoloration inhibitor such as benzotriazole, oxalide, anilide, salicylic acid, phosphous, sulfur, etc. compounds and at least one polymer resin (this composition exhibits antibiotic property and does not discolour with time, and can be employed to form a variety of products which require antibacterial and/or antifungus properties); (2) Transparent bactericidal multilayer sheets with haze <5% comprise a crystalline thermoplastic resin containing 0.05-5 phr granular zeolite containing bactericidal metal ions in a sheet comprised polypropylene containing 0.5% Bacterikiller BM 103 (zeolite A containing 3.5% Ag) [JP Pat. 04,275,142 (1992), Chisso Co., Japan]; (3) Antibacterial polyolefin compositions with inhibiting effects on the growth of bacteria and moulds contain polyolefins and 2-pyridinethiol 1-oxide and its metal (Zn) salts or other organic biocides (polypropylene 100, 2-(4-thioazolyl) benzimidazole 0.25 and Zn 2-pyridinethiol 1-oxide 0.25 part were roll kneaded at 230° C. and then hot pressed at 220° C. to give a 2 mm sheet, which completely inhibited of the growth of Aspergillus niger, Penicillium citrinium, Chaetomium globosum, Aurebasidium dulllans, and Gliocladium virens at 28° C. for 28 days) [JP Pat. 04,270,742 (1992), Shinto Paint Co. Ltd., Japan]; (4) Antibacterial heat-resistant polyolefin compositions comprising polyolefins (polypropylene)100, bactericidal metal ions (Ag, Cu, Zn and/or Sn ions supported on zeolites) 0.01-1.5, dimethylsiloxane oil 0.01-0.2, and aluminium borate whisker (9Al 2 O 3 .2B 2 O 3 ) 0.01-0.1 part showed good antibacterial action as tested against colon bacilli [JP Pat. 04,363,346 (1992), Tonen Kakagu Kk., Japan]; (5) JP 04,13,733 (1992) discloses antibacterial films for packaging chemicals and food which were prepared by treating one or two surfaces of films containing aluminosilicic acid salts with electrical corona (a composition containing 2 parts zeolite A (Ag content 6.7%, NH 4 content 0.5%) and polyamide (6-nylon 66 copolymer) were together extruded and exposed to electrical corona for 0.2-10 s to give an antibacterial film with good adhesion to ham, versus poor adhesion for the film not treated with said corona); (6) U.S. Pat. No. 5,614,568, 1995 (Mawatari, M., et al., Japan Synthetic Rubber Co., Ltd., Tokyo) claimed an antibacterial resin comprising (A) 100 parts by weight of aromatic alkenyl resin, specifically styrene resin, (B) 0.01-30 parts of an inorganic metal compound or a porous structure substrate which has been injected to ion-exchange with a metal ion selected from the group consisting Ag, Zn, Hg, Sn, Pb, Cd, Cr, Co, Ni, Mg, Fe, Sb and Ba, and (C) 0.01-30 parts of a polyethylene comprising —COOH, —COOM(salts), —OH, —COOR, and epoxy, anhydride and amine functional groups, a polypropylene comprising said selective functional groups with molecular weight 10000-30000; (7) Japan Chem. Ind. Co. (JP Pat. 09,176,370, 1997) discloses an antimicrobial injection-moldable polypropylene composition showing no discoloration or degradation during processing, storage and uses contain 0.2 phr of liquid paraffin, 1.0 phr of the mixture of inorganic compounds Ag 0.15 Na 0.5 H 0.35 , Zr 2 (PO 4 ) 3 and Mg 0.7 Al 0.3 O 1.15 which was used as an antimicrobial agent; (8) Polyethylene terephthalate films coated with thin Ag, Cu and Ti-layers by sputtering treatments have high antibacterial activity. The reducing in bacteria values of almost 100% were determined by the SEK Shake Flask Method and the Contacted Film Method [S. Kubota, et al, Bakin Bobai, 25 (7), 393 (1997); Chem. Abstr., 127, 122386s (1997)]; (9) Tokuda, et al, [JP Pat. 09,136,973, 1997] describes bactericidal packaging films comprising thermoplastic resins or blends on the base of PE, PP, PVC, polyesters and/or PS and calcined powder ceramics containing 40-60% of SiO 2 , 20-30% of Al 2 O 3 , 4-8% of ZnO, 2-5% TiO 2 and 0.1-1.0% Ag or Cu salts as an antibacterial agent (these films were prepared by mixing above ceramics with said polymers and forming into films or by spreading or printing above ceramic-containing resins on resin base films); (10) JP Pat. 09,123,264 (1997) discloses antibacterial decorative sheets and manufacture of decorative moldings (these sheets were prepared by shaking colored base sheets with thermosetting diallyl phthalate resin composition containing 0.5% of Ag/Zr phthalate, Ag tripolyphosphate, Ag hydroxyapatite, and/or (Ag/Ca) 3 phosphate. A printed paper sheet was hot pressed with a moldable polymer composition to form a waterproof pan for bathroom uses); (11) Bactericide-containing abrasive agents and resin moldings for video and arcade games comprise a thermoplastic resin (98% of polycarbonate) incorporated with fillers (1%) and bactericides (Ag-containing zeolite, Bactekiller) or bactericide-treated powders (1%) [Sumitomo Elect. Ind. Ltd., JP Pat. 09,77,880, 1997]; (12) JP Pat. 09,77,042 (1997) releases to antimicrobial synthetic resin containers for preserving drinking water (this container is prepared using synthetic resins with Ag-containing glass particles that release adequate amount of microbiocidal silver ions (Ag + ) into the water where growth of bacteria or fungi in the drinking water is prevented by these ions); (13) JP Pat. 09,002,517, 1998 [Taisho Pharmaceutical Co. Ltd. (Tokyo, Japan)] discloses a process for making a bottle and cap with antibacterial properties on their inner contact surfaces. Antimicrobial zeolite power (1 to 5% by weight) containing microbiocidal Ag, Zn and Cu ions is mixed with thermoplastic resins such as ethylene-vinylacetate copolymer, polypropylene and polyethylene (the zeolite is dispersed throughout the bottle and is present on both inner and outer surfaces and can also be used for both cap and membrane seal); (14) Polypropylene plastic table wares contain an antimicrobial agent (Amenitor) (JP Pat. 09,108,084, 1997); (15) Bactericide power (Bactekiller) or bactericide-treated power containing adhesive agent and resin moldings for video areade games were described (Chem. Abstr., 127, 35460t, 1997); (16) Silver (Ag)-zeolite antimicrobial agents for protection of the plastic films from various microorganisms were manufactered by Michubusi Co. Bactericide ceramic power containing 0.1-1.0% Ag or Cu, 2-5% TiO 2 , 4-8% ZnO or MnO 2 , 20-30% Al 2 O 3 and 40-60% SiC or SiO 2 was recommended to use in the varoious thermoplastic composition (polyolefin, polystyrene, polyesters, etc.), resins and binders [T. Ishitaki, High Polym. Japan, 39(10), 744 (1990); Y. Kajiura, Jidosha Gijutsu, 51(5), 34 (1997); JP Pat. 09,136,973 (1997)]; (17) Antimicrobial activities of some new coordination polymers were also discribed by Patel, et al. [B. Patel and M. Mohon, J. Polym. Mater., 13(4), 261 (1996)].
[0021] However, all these publications are related to the preparation and use of various antimicrobial polymer materials including non-orientated and non-multilayered polymer films, sheet, etc. containing bioactive metal ions. Thus the above patents describe inventions are essentially different from the present patent invention which is concerned with preparation of semi- and biaxialy oriented and multilayered antimicrobial thin films containing Ag + -containing polymeric bioactive agent only in the skin layer and having high physico-mechanical, thermal and antimicrobial properties. Another distinctive feature of these films is possibility of their use in the food packaging applications, where anti-fogging properties are required.
[0022] Several Firms such as Taisho Pharmaceutical Co. Ltd. (Tokyo, Japan), Kanebo Chemical Industries, Ltd. (Osaka, Japan), M. A. Hanna Company (ISA, Neutrabac™ Antibacterial Masterbatch), Wells Plastic Ltd. (Staffordshire, UK), etc. have already started to manufacture organic and inorganic antibacterial agents and various antimicrobial Masterbatches for use in thermoplastic polymer compositions.
[0023] Many organic and organoelement compounds having high biological activities are also used in polymer film-forming composition systems [Z. M. Rzaev, CHEMTECH, (1),58 (1976); Z. M. Rzaev et al., England Pat. 1,270,922 (1972); U.S. Pat. No. 4,261,914 (1981); U.S. Pat. No. 4,314,851 (1982); Z. M. Rzaev et al., Bioresistant Organotin Polymers, Chemistry, Moscow, 1996 (Russ.)]. Thus, (1) “ICI Biocides” Firm (UK) prepared and patented new water soluble biocides on the base of isothioazolione useful for the effective preservation of polymer resins, specially aqueous-based paints from bio-destruction with microorganisms in the stage of synthesis, storage and uses of these materials [C. L. P. Eacoff, Orient. J. Oil and Colour Chem. Assoc., 74 (9), 322 (1991)]; (2) Polen Kagaku Sangyo K.K. [JP Pat. 09,169,073, 1997] discloses antibacterial and antifungal sheets laminated with low expanded olefin polymer (such as HDPE) compositions containing 0.1-1.0% 2-(4-thioazolyl)benzimidazole as an antibacterial and antifungal agent showing good deep drawability; (3) Antimicrobial rubber articles contain ammonium salt of chlorohexidine as an antimicrobial agent [UK Pat. 8,919,152 (1990)]; (4) Biocide Cl-containing polyketones having antibacterial activity against selected yeast, fungi,—and bacteria were prepared by Fiedel-Graft [Friedel-Craft] reaction of o-cresol with chloroacetyl chloride, dichloromethane and dichloroethane in the presence of anhydrous AlCl 3 as a catalyst in nitrobenzene as solvent [B. T. Petel, et al, Orient. J. Chem., 13 (1), 83 (1997); Chem. Abstr., 127, 136122q (1997)]; (5) Polyethylene four-layered film was coated with mixture of allyl isothiocyanate (as a biocide), polyfunctional isocyanate, polyols and dibutyltin laurate (as a catalyst) to give a multilayered film with polyethylene outer layer having antibacterial activity [JP Pat. 09,151,317, 1997]; (6) Matsukawa Electric Works, Ltd. (Japan) was disclosed a method of preparing plastic table wares (plastic bowl) containing antimicrobial agents (Amenitop) by moulding. The core potion is formed with a polypropylene resin and this is coated with another polypropylene containing a said antimicrobial agent; (7) Kyowa Co. Ltd. [JP Pat. 09,135,716, 1997] patented the gas-permeable and antimicrobial bags for the medical application. These bags were prepared from cushion bases consisting open-celled polymer foams and bactericide-containing hydrophobic noncircular fiber; (8) p-Hydroxy butylbenzoate [JP Pat. 63,173,723 (1988)], 2-(4′-thiazolyl)-benzimidazole [U.S. Pat. No. 4,008,351 (1977)], Pt-vinylsiloxane complex [JP Pat. 04,202,313 (1993)], polymeric iodine complexes [U.S. Pat. No. 3,907,720 (1975), phosphate esters [U.S. Pat. No. 3,888,978 (1975), U.S. Pat. No. 3,991,187 (1976), U.S. Pat. No. 4,661,477 (1987), U.S. Pat. No. 4,935,232 (1990)] and 2,3,5,6-tetrachloromethylsulfonylpyridine (for preparation antibacterial styrene type resin compositions) [JP Pat. 07,82,440 (1995)] have also been recommended for use as bactericide and antimicrobial agent in the various polymer compositions, film and sheets.
[0024] There are a number of patents disclosing various polymer composits, thermoplastic fibers, sheets, coatings, films, etc. having biological activity toward different type of microorganisms [Shima et al., U.S. Pat. No. 4,000,102, 1976; Dell et al., U.S. Pat. No. 4,584,192, 1986; Fink et al., U.S. Pat. No. 4,751,141, 1988; Gillete et al., U.S. Pat. No. 5,152,946, 1992; Grighton et al., U.S. Pat. No. 5,246,659, 1993; 5,104,306, Apr. 14, 1992]. For example, (1) U.S. Pat. No. 5,178,495, 1993 discloses a polymeric film with biocide. A multi-ply film has been developed that includes a biocide in at least one the film layers. Said biocide mixed with the thermoplastic prior to extrusion of the sheet. This sheet with biocide can be used to construct water containment facilities for drinking water, fish farms and industrial use and can be used as a covering for water tanks or equipment in environments that promote microbial growth at the surface of the film; (2) U.S. Pat. No. 5,777,010 1998 (Nohr R. S., et al., Kimberly-Clark Worlwide, Inc., Neenah, Wis.) discloses melt-extrudable composition containing antimicrobial siloxane quaternary ammonium salts. These compositions which includes a thermoplastic polyolefin and a siloxane quaternary ammonium salt additive. Upon melt extruding the thermoplastic composition to form fibers and non-woven webs, or other shaped artides, the surfaces of such shaped articles exhibit antimicrobial properties. (3) Early, antimicrobial siloxane quaternary ammonium salts were patented [U.S. Pat. No. 5,567,372, 1994 and U.S. Pat. No. 5.569,732, 1994] and published [ Nohr R. S., et al., J. Biomed. Sci., Polym. Ed., 5(6), 607 (1994)] (U.S. Pat. No. 5,567,372, 1994 discloses a method of preparing a non-woven web containing antimicrobial siloxane quaternary ammonium salts); (4) U.S. Pat. No. 5,527,570 [Addeo, A., et al.,1996, Centro Sviluppo Settori Impiego SRL, Milan, Italy)] relates to a multilayer and multifunctional packaging elements having high-absorption activity toward aqueous liquid substances as well as barrier properties toward gases such as oxygen and carbon dioxide are prepared by thermoforming (Each layer comprises a polymeric thermoplastic material. Intermediate layer of this packaging element may also contain antibacterial agents); (5) U.S. Pat. No. 5,142,010, 1992 (Olstein, A. D. et al., H. B. Fuller Licensing & Financing Inc., Wilmington, Del.) discloses polymeric biocidal agents containing carboxyl groups, fluorene substitute and alkyl C 1-20 groups, and any bioactive naturally occurring amino-acid chain (the resulting polymers are disclosed to be useful in any variety of applications requiring an antimicrobial agent or an active sanitizer or disinfectant including films, coatings and adhesives, as well as also being useful in medial, food preparation and personal care product applications; (6) Describes an antimicrobial film-forming compositions containing bioactive polymers (homo-, co- and terpolymers of monomers containing pyran groups) having pendant pyran groups [Greenwald R. B. et al., U.S. Pat. No. 5,108,740, 1992, Ecolab Inc., St. Paul, Minn.] (this publication describes a liquid composition that yields an abrasion resistant polymeric film on a surface that provides extended protection from microbial growth through slow release of a potent antimicrobial agent).
[0025] As evident from the above described patent publications, there is relatively small number of patent publications describing polyolefin based, in particular, mono- and biaxially oriented polyolefin based films, and all of patent publications suffer from one or more of the following properties: not being multilayered and oriented polyolefin non-opaque films, not being heat-sealable; not having antimicrobial properties using thin films containing Ag + -containing polymeric bioactive agent only in the skin layer, not having antifogging properties.
SUMMARY
[0026] It is an object of the present invention to design and prepare a multilayer structure (having at least an antifogging and antimicrobial skin layer (A)/a core layer (C)/an outer layer (E) structure) for semi and biaxially oriented polyolefin based antifogging films having advantageous properties as compared with known and commercial films such as low values of haze, high values of sheen, lower longitudinal and transverse shrinkage, which provides high dimensional stability, and excellent antifogging and antimicrobial properties. Preferably the antifogging and antimicrobial skin layer (A) is electrical corona or flame treated. Electrical corona or flame treatment of the the outer layer (E) may enhance ink anchorage and increase the printability of this layer. Preferably, the films comprise an inner (B) layer between the antifogging and antimicrobial skin layer (A) and the core layer (C). More preferably, the inner (B) layer has the same composition as antifogging and antimicrobial skin layer (A) without the antimicrobial additives. Preferably, the films may comprise a second inner (D) layer between the outer (E) layer and the core layer (C). More preferably, the second inner (D) layer has a preferred composition of 100 percent (%) E-P-B terpolymer.
[0027] Antimicrobial and antifogging ≧3 layers polymer films with preferable A/C/E structure useful for the food, medicine and agriculture applications as well as for other general packaging and non-traditional special applications. More preferably, antimicrobial and antifogging films having a A/B/C/E structure. Most preferably, biaxially oriented polypropylene films having symetrical structure A/B/C/D/E, where two outer layers A and E are having antimicrobial and antifogging properties and heatsealable and two intermediate layers B and D are made of E-P random copolymers or E-P-B terpolymers, with or without antifogging agents.
[0028] A preferred embodiment of antifogging and antimicrobial skin layer (A) comprises the following compositions: polypropylene greater than or equal to 1 percent (wt. %), E-P-B terpolymer or E-P random copolymer greater than or equal to 70 percent (wt. %), a mixture of glycerol monostearate (GMS) and diethanolamine (DEA) greater than or equal to 0.2 percent, special additive greater than or equal to 0.1 percent, an antiblocking agent greater than or equal to 0.2 percent (wt. %) of synthetic silica or zeolite and an antimicrobial agent greater than or equal to 0.1 percent (wt. %) of Ag + -containing inorganic polymer of linear structure. More preferably, each component of skin layer (A) has a percentage in the following ranges (the total of all components for any specific embodiment would, however, equal 100 percent (wt. %)): polypropylene between 1 and 5 percent (wt. %), E-P-B between 90 and 98 percent (wt. %), a mixture of GMS and DEA between 0.2 and 0.5 percent (wt. %) where the GMS concentration in the mixture may vary from 1% to 99%, and special additive (a mixture of higher fatty acid ester of polyvinyl alcohol or polyether polyol, where respective ratios may vary from 1% to 99%) between 0.1 and 0.5 percent (wt. %) and an antiblocking agent between 0.1 and 0.25 percent (wt. %) of synthetic silica, polymethylmetacrylite or zeolite and an antimicrobial agent between 0.2 and 1.0 percent (wt. %) of Ag + -containing inorganic polymer of linear structure.
[0029] Preferably, inner layer (B) has the composition totals: polypropylene greater than or equal to 1 percent (wt. %), E-P-B terpolymer. or E-P random copolymer greater than or equal to 70 percent (wt. %), and a mixture of glycerol monostearate(GMS) and diethanolamine(DEA) greater than or equal to 0.2 percent, special additive greater than or equal to 0.1 percent, More preferably, each component of antifogginner layer (B) has a percentage in the following ranges (the total of all components for any specific embodiment would, however, equal 100 percent (%)): polypropylene between 1 and 5 percent (%), E-P-B between 90 and 98 percent (%), a mixture of glycerol monostearate(GMS) and diethanolamine(DEA) greater than or equal to 0.2 percent, special additive greater than or equal to 0.1 percent, an antiblocking agent greater than or equal to 0.2 percent (wt. %) of synthetic silica. More preferably, each component of antifogging inner layer (B) has a percentage in the following ranges (the total of all components for any specific embodiment would, however, equal 100 percent (%)): polypropylene between 1 and 5 percent (%), E-P-B between 90 and 98 percent (%), a mixture of GMS and DEA between 0.2 and 0.5 percent (wt. %) where the GMS concentration in the mixture may vary from 1% to 99%, and special additive (a mixture of higher fatty acid ester of polyvinyl alcohol or polyether polyol, where respective ratios may vary from 1% to 99%) between 0.1 and 0.5 percent (%) and an antiblocking agent between 0.1 and 0.25 percent (wt. %) of synthetic silica or zeolite. This inner layer does not have antimicrobial agent.
[0030] In a preferred embodiment, second inner Layer D has a preferred composition of 100 percent (%) E-P-B terpolymer or E-P random copolymer Further, outer layer E has the same preferred and more preferred compositions as either of layers A or D.
[0031] Finally, a preferred embodiment of core layer C comprises the following compositions (the total of all components for any specific embodiment would, however, equal 100 percent (%)): polypropylene greater than or equal to 95 percent (wt %), a mixture of GMS and DEA , would be greater than or equal to 0.2 percent (wt %) and special additive equal or greater than 0.1 percent (wt %) More preferably, each component of layer C has a percentage in the following ranges: polypropylene between 97.5 and 99.5 percent (wt. %), a mixture of GMS and DEA between 0.2 and 0.5 percent (wt. %) where the GMS concentration in the mixture may vary from 1% to 99%, and special additive (a mixture of higher fatty acid ester of polyvinyl alcohol or polyether polyol, where respective ratios may vary from 1% to 99%) between 0.1 and 0.5 percent (wt. %)
[0032] Antifogging and Ag + -containing antimicrobial biaxially oriented polypropylene (BOPP) films, can be prepared by using the tandem extruder system with two extruders supplied with two, three or four satellite co-extruders, flat die, chill roll, corona discharge (onto the skin layer or, alternatively, both the skin layer and the outer layer) and recycling line as well as the mono- and semi-oriented cast film technology with temperature controlled mold. After mono- and biaxially stretching (4-7 times at 105-140° C. in the machine direction, MD and 7-11 times at 150-190° C. in the transverse direction, TD) and air corona discharged of one outer surface in the given conditions. Preferably, the antifogging and antimicrobial films have the following characteristics: specific density of 0.91 g/cm 3 , low haze around 1.5% (+−0.2), high gloss greater than or equal to 95%, heat sealability around 120° C., excellent dyne level retention (preferably equal or greater than 40 dynes/cm) for good printability and antifogging characteristics, excellent antifogging properties (rated ‘E’ according to ICI's cold fog test method, which means that the antifogging surface of the film is almost free of big water droplets which makes it invisible) and excellent antimicrobial activity (99.9%) toward various microorganisms, especially and preferably against three common bacteria Staphylococcus aureus, Escherichia. coli and Salmonella enteritidis.
[0033] One the other hand, this invention also provides longer shelf life for the freshcut and pre-packed vegetables, salads, fruits and like, due to the high biological activity of the antimicrobial agent which prevents the certain bacteria's growth. Another advantage of the present invention is the easy processability of the antimicrobial agent whose processing conditions are within the processing windows of the ingredients put in the conventionalal or antifogging BOPP films. In fact this advantage is provided by the high thermal stability of the antimicrobial agent which is >300° C. and which is well above of the operating temperatures of the raw materials present in BOPP or antifogging BOPP films. In other words, under normal processing conditions of BOPP film manufacturing, the said antimicrobial agent does not show chemical degradation or decomposition.
[0034] Another important advantage of the present invention is the high degree of antimicrobial performance against the certain bacteria by using only a very low concentration of antimicrobial agent, due to its usage only in the very thin layer(s). This very low concentration of antimicrobial agent in the polymer matrix is preferably 30 times lower, as compared with conventional biocides used in known polymer compositions, due to its only use of a thin antifogging and antimicrobial skin layer (A), preferably between 0.5-1.5 μm. The usage of so low concentration of antimicrobial agents advantageously reduces the cost of the film.
[0035] Another aspect of the present invention is the possibility to production of the films in the form of mono-oriented and biaxialy oriented multilayer thin films with similar component and layer compositions by using cast film technology and tandem extruder system technology, respectively. According to the present invention the technological aspects of manufactured process of said films are (1) multilayered and mono-oriented cast film technology and (2) tandem extruder system technology by the fact that tandem extruder system with two main extruders for better homogenity and dispersion of the raw materials, supplied with three satellite co-extruders, recycling line and corona discharge. The process is carried out by three chill-roll or water bath treatments and two step of longitudinal orientation allowing to prepare good homogenized film with matte appearance having improved surface properties and dimensional stability. The skin layer or, alternatively both the skin layer and the outer layer, of biaxially oriented films prepared may be treated in a known manner by flame or more preferably, by electrical corona discharge. The use of said recycling line for film waste forming in the transverse stretching stage allows to lower film cost For example (as a preferred, but not the only embodiment of the process), after coextrusion, an extruded five-layer film is taken off over the corresponding process steps through a chill roll and cooled, and cast film profile is controlled by β-Gauge equipment. The film is subsequently stretched longitudinally at two steps and stretched transversely. After biaxially orientation, the film is set and electrical corona-treated on one or two sides. The following conditions are preferrable: (1) Extrusion: extrusion temperature 170-260° C., first chill roll temperature 10-45° C.; (2) Machine (longitudinal) stretching: stretching roll temperature of first step 105-120° C. and second step 115-140° C., longitudinal stretching ratio 4:1-6:1 for first step and 1:1-1:2 for second step; Transverse stretching: temperature of heat-up zones 150-185° C., temperature of stretching zones 155-185° C., transverse stretching ratio 7.5:1-11:1; Recycling: edges of the biaxially orientated film is recycled and fed to the line again; Setting: setting temperature 165-185° C.; electrical corona discharge (A side only or alternatively both A and E sides, together): voltage 10-25 kV and frequency 1.5-30 kHz. The following preferable conditions for the multilayered mono-oriented (in MD only) antimicrobial films in accordance with cast film technology in detail are selected: (1) extrusion temperature 250° C. by using temperature cotrolled MITSUBISHI type die, (2) chill roll temperature 10° C. (3)film profile is controlled by β-Gauge equipment, (3) the speed of film production line 100 m/min, and (4) level of air corona discharge on A surface of the film is 11 Kw
[0036] It is further object of the present invention to widen the field of application of said films useful for the food, medicine and agriculture applications as well as for other general packaging and non-traditional special applications including bioprotection of food contacting materials and food handling areas, medicine devices, agriculture products as well as applications in potential areas like food-storage containers, in oral hygienic products, hospitals and other health institutions to provide hygienic conditions, for preserving drinking water and as a covering for water tanks, etc.
[0037] Another aspect of the present invention is to use new systems of additives, i.e—a mixture of GMS and DEA, special additive (a mixture of higher fatty acid ester of polyvinyl alcohol or polyether polyol) as antifogging agents, in combination with the antimicrobial agent Ag + , to create dual-effect polymeric films having both antifogging and antimicrobial properties.
[0038] Those additive systems are used with the following compatible polyolefins selected from polypropylene, a propylene-ethylene random copolymer, propylene-butene-1 random copolymer or an ethylene-propylene-butene-1 terpolymer with various compositions, where the last three are used for the heat sealable skin layers.
[0039] Advantages of antifogging and antimicrobial films are: (1) Antimicrobial activity against certain bacteria, (2) excellent antifogging properties (3) high antimicrobial performance in comparative low concentration of antimicrobial agent, (4) preservation of antimicrobial activity during the long time of storage. of the polymeric films, even after corona or UV-treatment, (5) low total migration properties with the diluents distillated water, acetic acid, ethyl alcohol, heptane and olive oil as mentioned in the directives of EEC and FDA allowing to use of these films in food packagings, (6) high optical properties (low haze, high sheen), (7)high physical-mechanical properties (8) possibility of use various thermoplastic film-forming polymers in core layer of films, and (9) wide range of conventional and special application fields of invented films.
DESCRIPTION
[0040] The present invention is an antifogging and antimicrobial film that is a multi-layered, oriented and made from polyolefins (polypropylene (PP), propylene-ethylene random copolymers, ethylene-butylene random copolymers and/or ethylene-propylene-butylene (E-P-B) terpolymers with various contents of E- and B- units). The present invention is useful for food packaging, food-wrapping, agricultural and horticultural applications, or any application where there is any condensation of water vapor on the various surfaces in the form of droplets and effectiveness of certain bacteria needs to be reduced.
[0041] The following Examples of the present invention for preparation of multilayered antifogging and antimicrobial films with different composition, properties are illustrated.
EXAMPLE 1
[0042] A first example of a multilayer film (A/C/E) having antifogging and antimicrobial properties comprises: (A) 1.0 μm antifogging and antimicrobial skin layer containing 92.25% by weight of said ethylene-propylene-n-butylene-1 terpolymer with given composition ( ethylene [C 2 ]=1.5-4.5%, n-butylene-1 [C 4 ]=3.0-15.0%), 0.25% by weight of zeolite as an antiblocking agent, 6.0% by weight of polypropylene homopolymer, and 1.0% by weight of Ag + —as an antibacterial and antimicrobial agent (in derived from a masterbatch having 20% active agent-Ag.+, in a polypropylene carrier: the active is a “silver containing glass powder”, this has the CAS No: 65997-17-3, EINECS No: 266-046-0, and EPA, Reg No: 73148 Issue date: 1 Sep. 2000), 0.20% by weight of glycerol monostearate and 0.20% by weight of diethanolamine and 0.10% by weight of special additive (a mixture of higher fatty acid ester of polyvinylalcohol or polyether polyol) as antifogging and antistatic agent, (C) 28.0 μm core layer (C) from 99.5% by weight of virgin or marked (5-cholesten-3β-ol as a marking agent) polypropylene homopolymer, 0.20% by weight of glycerol monostearate and 0.20% by weight of diethanolamine and 0.10% by weight of special additive (a mixture of higher fatty acid ester of polyvinylalcohol or polyether polyol) as antifogging and antistatic agent and (E) 1.0 μm outer layer having 99.75% by weight E-P-B terpolymer and 0.25% by weight zeolite. This (E) layer does not exhibit any antifogging or antibacterial property. After biaxially stretching the film (5.5 times at 120° C. in the (longitudinal direction, MD and 8 times at 170° C. in the transverse direction, TD) and electrical corona discharged skin layer (A). Layer (A) has corona treatment in order to accelerate the migration of the antifogging agents and alternatively, outer layer (E) has also corona treatment for further printing purposes.
EXAMPLE 2
[0043] A second example of a multilayer film comprises the same thickness structure and composition as in Example 1 with the following changes: the core layer (C) comprises 100% of polypropylene homopolymer.
EXAMPLE 3
[0044] A third example of a multilayer film comprises an A/C/E structure but with the following changes in Example 1: the antifogging and antimicrobial skin layer (A) is 1.5. μm thick, the core layer (C) is 27.0 μm thick and the non-antifogging, non-antimicrobial outer layer (E) is 1.5. μm thick. After biaxially stretching, heat setting and corona discharged in the given conditions, that film has antifogging and antibacterial properties on skin layer (A), whereas the outer layer (E) is useful for printing and heat seal applications.
EXAMPLE 4
[0045] A fourth example of a multilayer film comprises A/C/E thickness structure and composition as in Example 3 with following changes: Outer layer (E) has also antifogging properties but no antimicrobial property. Thus, outer layer (E) has the same antifogging agents in layer (A) of Example 1 but not Ag + which provides antimicrobial effect. Film with that structure is produced as described above.
EXAMPLE 5
[0046] A fifth example of a multilayer film comprises A/C/E thickness structure and composition as in Example 4 with following changes: Outer layer (E) has the antifogging and also antimicrobial properties where each of layers (A) and (E) are 1.5 μm thick and have the chemical composition of the skin layer (A) in Example 1. The core layer (C) is 27.0 μm thick and has the same chemical composition as given in Example 3. This film shows antifogging and antibacterial properties and corona treatment on both sides.
EXAMPLE 6
[0047] A sixth example of a multilayer film comprises A/B/C/D/E structure with the following changes in the Example 5: inner layer (B) and second inner layer (D) has the same chemical compositions as skin layer (A) and outer layer (E) where each of the four skin layers is of 0.75 μm thick. This symmetrical five layered composition provides the same excellent antifogging and antibacterial properties on both sides. Furthermore, the structure of this example also avoids the low output capacity of the single satellite extruders which limits the total output of the manufacturing line by giving high total extrusion output. Corona discharge on each side of this film also gives the flexibility of using either side by converters or packers.
EXAMPLE 7
[0048] A seventh example of a multilayered film comprises A/B/C/D structure with following changes in Example 6: the second inner layer (D) becomes the outer layer (E), having the same chemical composition of the layers (A) and (B) but with a thickness of 1.5 μm. This film exhibits antifogging and antibacterial properties on both sides.
EXAMPLE 8
[0049] A eighth example of a multilayer film comprises A/B/C/D/E structure and chemical composition given in Example 6, except the thickness of the core layer (C) which is 32.0 μm, giving the whole structure 35.0 μm total thickness.
EXAMPLE 9
[0050] A ninth example of a multilayer film comprises A/B/C/D/E structure and chemical composition given in Example 6, except the following changes: inner layer (B) and second inner layer (D) do not have the antimicrobial agent Ag + , and the thickness of the core layer (C) which is 22.0 μm, giving the whole structure 25.0 μm total thickness.
[0051] Layer compositions of the above mentioned examples were given in Table: 1 and the physical-mechanical properties of those films were given in Table:2.
[0052] Analysis of the initial materials used and films prepared was done according to known standard measurement methods. For example:
Specific density was determined according to ISO 1183 and/or ASTM D-1505. Melt Flow Index (MFI) was measured according to an ASTM 1238/L at 230° C. and under the load of 21.6 N. Melting point (m.p.) was measured by DSC method, maximum point of the melting curve, at a heating rate of 10° C./min. Vicat softening point was determined according to ASTM D-1525. Izod impact strength was measured according to ISO 180/1A. Tensile strength and elongation at,break were determined according to ASTM D-882. Haze of the film was measured according with ASTM D-1003. Dynamic friction coefficient of the film was determined according to ASTM D-1984. Sheen of the film was measured according to ASTM D-2103, the angle of incidence was set at 45°. Shrinkage of the film was measured according to ASTM D-2104. The test sample was shrunk at 120° C. for a period of 5 minutes. Water vapor transmission of the film was measured according with ASTM E96. Oxygen permeability of the film was measured according with ASTM D-1434. Surface tension of the film, after surface ionization by electrical corona discharge and after storage for 6 months, was measured according to ASTM D-2578. Antifogging property of the film was evaluated using ICI's the “Cold-Fog” test method (ICI publication 90-6E) for food packaging film.
[0054] The “Cold-Fog” test results of the films according to the present invention (E1-E9), and known patented and commercial antifogging films are summarized in Table 3. The test method is as follows: put tap water, 200 ml, in a 250 ml beaker and cover the top of the beaker with a sample of the test film; place the beaker in a temperature controlled refrigerator at 4° C. Observe the appearance of the film for a total period of one week. It was shown that the films of the present invention, as compared with known patents and commercial films have superior antifogging appearance and properties.
[0055] The test method used to measure the antibacterial properties of the present invention is a viable count method. An inoculum, which is a nutrient broth containing a known number of bacteria (there should be 10 5 -10 6 bacteria in the initial inoculum), is placed directly onto the BOPP film. A piece of standard (not antimicrobial) film is placed over the inoculum to ensure intimate contact between the inoculum and the test film and to prevent the inoculum drying out. The sample is covered with the lid of a petri dish and incubated at 35 deg C. and 90% Relative Humidity (ideal conditions for bacterial growth). After incubation the inoculum is washed off the samples, serially diluted and plated out onto Agar plates. These plates are incubated and counts of the still viable (i.e. bacteria able to reproduce and form visible colonies) are counted. Antibacterial test results of the films of the present invention were given Graph 1-3.
[0056] Food contact approval tests of the present invention also had been done. Accordingly, Global Migration tests of the preferred embodiment film examples described herein have been found in compliance with the following regulations: EEC Regulation 90/128/EEC and amendments (up to and including 99/91/EEC) and FDA Section 21 CFR Ch. 1 175.300 and 176.170. Those results were tabulated in Table: 4
[0057] According to the present invention, the technological aspect of manufactured process of said films is distinguished from known processing by using the tandem extruder system with two main extruders supplied with two or three satellite co-extruders, recycling line and corona discharge. Other processes of manufacturing said films are known to those skilled in the art. The process is carried out by three chill-roll treatments and two steps of longitudinal orientation followed by the orientation in the transverse direction allowing the preparation of good homogenized antifogging films with improved surface properties and dimensional stability. One or both surface of biaxially oriented films prepared are treated in a known manner by corona discharge. After extrusion, the extruded film having at least 3 layers is taken off over the corresponding process steps through a chill roll and cooled, and cast film profile is controlled by B-Gauge equipment. The film is subsequently stretched longitudinally in two steps and stretched transversely. After biaxially orientation, the film is thermally set and air corona treated on one or two sides. The following are typical manufacturing conditions in detail: (1) Extrusion: extrusion temperatures 170-260° C., first chill roll temperature 10-45° C.; (2) machine direction (longitudinal) stretching: stretching roll temperature of first step 105-120° C. and second step 115-140° C., longitudinal stretching ratio 4.5:1-6:1 for the first step and 1:1-1:2 for the second step; Transverse stretching: temperature of heat-up zones 150-185° C., temperature of stretching zones 155-185° C., transverse stretching ratio 7.5:1-11:1; Recycling: edges of the biaxially oriented film is recycled and fed into the line again; Heat setting: setting temperature 165-185° C.; Air corona discharge: 11 Kw.
[0058] While these descriptions directly describe the above embodiments, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiments shown and described herein. Any such modifications or variations that fall within the purview of this description are intended to be included therein as well. It is understood that the description herein is intended to be illustrative only and is not intended to be limitative. Rather, the scope of the invention described herein is limited only by the claims appended hereto.
TABLE 1 Layer compositions for antifogging-antibacterial films of the present invention. Layer Compositions Exp A skin layer B inner layer C core layer D second inner layer E outer layer E1 1.0 μm — 28 μm — 1.0 μm (1) PP-4.02% PP-97.5% E(2.5%)-P-B(4.5%) (2 )E(2.5)-P-B(4.5%) GMS-0.20% Terpolymer 99.75% Terpolymer-92.25% DEA-0.20% Zeolite-0.25% E-P R.Copo-2.0% E-P R.Copo-2.0% (3 GMS-0.20% Special Additive-0.10% (4 DEA-0.20% (5 )Special Add.-0.10% Zeolite-0.23% Ag+-1.0% E2 1.0 μm — 28 μm — 1.0 μm PP-4.02% PP-100.00% E(2.5%)-P-B(4.5%) E(2.5)-P-B(4.5%) Terpolymer 99.75% Terpolymer-92.25% Zeolite-0.25% E-P R.Copo-2.0% GMS-0.20% DEA-0.20% Special Additive-0.10% Zeolite-0.23% Ag+-1.0% E3 1.5 μm 27 μm 1.5 μm PP-4.02% PP-97.5% E(2.5%)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% Terpolymer 99.75% Terpolymer-92.25% DEA-0.20% Zeolite-0.25% E-P R.Copo-2.0% E-P R.Copo-2.0% GMS-0.20% Special Additive-0.10% DEA-0.20% Special Additive-0.10% Zeolite-0.23% Ag+-1.0% E4 1.5 μm 27 μm 1.5 μm PP-4.02% PP-97.5% E(2.5%)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% Terpolymer 97.25% Terpolymer-92.25% DEA-0.20% E-P R.Copo-2.0% GMS-0.20% E-P R.Copo-2.0% DEA-0.20% DEA-0.20% Special Additive-0.10% GMS-0.20% E-P R.Copo-2.0% Special Additive-0.10% Special Additive-0.10% Zeolite-0.25% Zeolite-0.23% Ag+-1.0% E5 1.5 μm 27 μm 1.5 μm PP-4.02% PP-97.5% PP-4.02% E(2.5)-P-B(4.5%) GMS-0.20% E(2.5)-P-B(4.5%) Terpolymer-92.25% DEA-0.20% Terpolymer-92.25 GMS-0.20% E-P R.Copo-2.0% % GMS-0.20% DEA-0.20% Special Additive-0.10% DEA-0.20% E-P R.Copo-2.0% E-P R.Copo-2.0% Special Additive-0.10% Special Additive-0.10% Zeolite-0.23% Zeolite-0.23% Ag+-1.0% Ag+-1.0% E6 0.75 μm 0.75 μm 27.00 μm 0.75 μm 0.75 μm ) PP-4.02% PP-4.02% PP-97.5% PP-4.02% PP-4.02% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) Terpolymer-92.25% Terpolymer-92.25% DEA-0.20% Terpolymer-92.25% Terpolymer-92.25% ) GMS-0.20% GMS-0.20% Special Additive-0.10% GMS-0.20% GMS-0.20% ) DEA-0.20% DEA-0.20% E-P R.Copo-2.0% DEA-0.20% DEA-0.20% Special Add.-0.10% Special Additive-0.10% Special Additive- Special Additive-0.10% E-P R.Copo-2.0% E-P R.Copo-2.0% 0.10% E-P R.Copo-2.0% Zeolite-0.23% Zeolite-0.23% E-P R.Copo-2.0% Zeolite-0.23% Ag+-1.0% Ag+-1.0% Zeolite-0.23% Ag+-1.0% Ag+-1.0% E7 0.75 μm 0.75 μm 27.00 μm 1.50 μm PP-4.02% PP-4.02% PP-97.5% PP-4.02% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% E(2.5)-P-B(4.5%) Terpolymer-92.25% Terpolymer-92.25% DEA-0.20% Terpolymer-92.25% GMS-0.20% GMS-0.20% Special Additive-0.10% GMS-0.20% DEA-0.20% DEA-0.20% E-P R.Copo-2.0% DEA-0.20% Special Additive-0.10% Special Additive-0.10% Special Additive- E-P R.Copo-2.0% E-P R.Copo-2.0% 0.10% Zeolite-0.23% Zeolite-0.23% E-P R.Copo-2.0% Ag+-1.0% Ag+-1.0% Zeolite-0.23% Ag+-1.0% E8 0.75 μm 0.75 μm 32.00 μm 0.75 μm 0.75 μm PP-4.02% PP-4.02% PP-97.5% PP-4.02% PP-4.02% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) Terpolymer-92.25% Terpolymer-92.25% DEA-0.20% Terpolymer- Terpolymer-92.25% GMS-0.20% GMS-0.20% Special Additive-0.10% 92.25% GMS-0.20% DEA-0.20% DEA-0.20% E-P R.Copo-2.0% GMS-0.20% DEA-0.20% Special Additive- Special Additive-0.10% DEA-0.20% Special Additive-0.10% 0.10% E-P R.Copo-2.0% Special Additive- E-P R.Copo-2.0% E-P R.Copo-2.0% Zeolite-0.23% 0.10% Zeolite-0.23% Zeolite-0.23% Ag+-1.0% E.P R.Copo-2.0% Ag+-1.0% Ag+-1.0% Zeolite-0.23% Ag+-1.0% E9 0.75 μm 0.75 μm 32.00 μm 0.75 μm 0.75 μm PP-4.02% PP-5.02% PP-97.5% PP-5.02% PP-4.02% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) GMS-0.20% E(2.5)-P-B(4.5%) E(2.5)-P-B(4.5%) Terpolymer-92.25% Terpolymer-92.25% DEA-0.20% Terpolymer- Terpolymer-92.25% GMS-0.20% GMS-0.20% E-P R.Copo-2.0% 92.25% GMS-0.20% DEA-0.20% DEA-0.20% Special Additive-0.10% GMS-0.20% DEA-0.20% Special Additive- Special Additive-0.10% DEA-0.20% Special Additive-0.10% 0.10% Zeolite-0.23% Special Additive- E-P R.Copo-2.0% E-P R.Copo-2.0% E-P R.Copo-2.0% 0.10% Zeolite-0.23% Zeolite-0.23% Zeolite-0.23% Ag+-1.0% Ag+-1.0% E-P R.Copo-2.0% (1) Polypropylene homopolymer having MFI 1.8-3.5 gr/10 min, at 230° C., under 2.16 Kg. Load, mp = 164-166° C. (2) E-P-B Terpolymer having MFI 5.0-8.5 gr/10 min, at 230° C., under 2.16 Kg. Load, mp = 130-145° C. (3) GMS: Glycerolmonostearate (4) DEA: Diethanolamine (5) Special Additive: Mixture of higher fatty acid acid esters of polyvinyl alcohol or polyether polyol.
[0059]
TABLE 2
Physical-mechanical properties of the present invention (E1-E9),
patented (A), and commercial (B) antifogging films.
Patented
Films
Properties
E1
E2
E3
E4
E5
E6
E7
E8
E9
A*
B*
Total thickness (μm)
30
30
30
30
30
30
30
35
25
19
31
Thickness of core layer
28
28
27
27
27
27
27
32
22
—
—
(μm)
Yield (m 2 /kg)
36.6
36.6
36.6
36.6
36.6
36.6
36.6
31.4
43.9
—
—
Specific density (g/cm 3 )
0.91
0.91
0.91
0.91
0.91
0.91
0.91
0.91
0.91
0.91
0.92
Haze (%)
1.7
1.6
1.7
1.6
1.8
1.9
1.9
1.7
1.5
3.1
9.9
Sheen (gloss),
95.2
96.6
96.8
95.2
96.2
95.8
95.3
96.3
97.4
86.6
66.4
45° (%)
Shrinkage,
120° C./5 min (%)
In MD
3.0
3.5
3.5
3.0
3.0
3.5.
3.0
3.0
3.2
3.5
4.5
In TD
1.0
0.5
1.0
1.0
0.5
1.0
0.5
1.0
1.0
0.25
2.0
Tensile strength at break
13.8
12.6
14.2
12.9
12.3
14.1
12.8
12.3
12.1
13.5
13.6
(kg/mm 2 ), in MD
In TD
26.4
24.2
27.3
24.1
27.4
26.8
28.7
25.4
25.7
30.7
25.1
Elongation break (%)
In MD
195
193
196
195
198
197
195
185
193
218
183
In TD
58
57
58
59
56
58
58
55
50
50
65.9
Water vapor transmission
4.1
4.3
4.1
4.2
4.4
4.2
4.2
4.0
5.7
≧15
—
(g/m 2 24 h atm 20° C.)
Oxygen permeability
1570
1595
1540
1615
1565
1605
1570
1450
1950
≧3000
—
(cc/m 2 24 h atm 20° C.)
Friction coefficient,
0.23
0.28
0.25
0.23
0.25
0.27
0.25
0.25
0.22
0.23
0.22
Film/Film
Film/Metal
0.20
0.22
0.18
0.20
0.22
0.20
0.22
0.20
0.25
0.22
0.25
Heat seal initiation
120
120
120
120
120
120
120
120
120
125
125
temperature
at g/10 mm (° C.)
Antifogging property**
E
E
E
E
E
E
E
E
E
D
C
Surface tension(after
40/
40/
40/
40/
40/
40/
40/
40/
40/
37/39
37/32
storage for 6 months)
40
40
40
40
40
40
40
40
40
(nM/m)
*A - U.S. Pat. No. 4,876,146
*B - Commercial film
**E (Excellent), D (Good), and C (Poor) in accordance with ICI “Cold-Fog” test method.
[0060]
TABLE 3
Antifogging properties of the present invention (E1-E9),
patented and commercial antifogging films.
Antifogging properties of films obtained
by ICI “Cold-Fog” test method*
Antifogging side(s)
Example
of the examples of
No.
the present invention
Description
Performance
Rating
Comments
E1
A
A transparent
Excellent
E
Completely
film displaying
Transparent
no visible water
E2
A
As in E1
Excellent
E
As in E1
E3
A
As in E1
Excellent
E
As in E1
E4
A, E
As in E1
Excellent
E
As in E1
E5
A, E
As in E1
Excellent
E
As in E1
E6
A, E
As in E1
Excellent
E
As in E1
E7
A, E
As in E1
Excellent
E
As in E1
E8
A, E
As in E1
Excellent
E
As in E1
E9
A, E
As in E1
Excellent
E
As in E1
Patented
—
Randomly
Good
D
Discontinuous
scattered
film of water
transparent
drops
Commercial
—
A complete
Poor
C
Poor Visibility,
layer of large
lens effect,
transparent
dripping
drops
As described in ICI publication 90-6E entitled “Antifog Evaluations Tests for Agricultural and Food-Packaging Film”:
[0061] Agricultural and Food-Packaging Film.
Description Performance Rating Comments An opaque layer of small fog Very poor A Zero visibility droplets An opaque or transparent Poor B Zero visibility layer of small fog droplets A complete layer of Poor C Poor visibility large transparent droplets Randomly scattered Good D Discontinous large droplets film of water A transparent film with Excellent E Completely no visible water transparent
[0062]
TABLE 4
Global migration test results of antifogging and
antimicrobial film in accordance with EEC
Regulation 90/128/EEC and amendments
(up to and including 99/91/EEC) and
FDA Section 21 CFR Ch. 1 175.300 and 176.170
Food Simulant
Test Conditions
Mean Result
Olive oil
10 days @ 40° C.
2.0 mg/dm2
Distilled water
10 days @ 40° C.
0.2 mg/dm2
3% w/w Ace. Acid
10 days @ 40° C.
0.1 mg/dm2
10% v/v EtoH
10 days @ 40° C.
0.2 mg/dm2
n-Heptan
30 mins @ 70° F.
0.9 mg/in2
Distilled water
24 hrs @ 120° F.
<0.01 mg/in2
10% v/v EtoH
24 hrs @ 120° F.
<0.01 mg/in2
[0063] | Antimicrobial and antifogging polymeric films with preferable A/C/E structure useful for the food, medicine and agriculture applications as well as for other general packaging and non-traditional special applications. More preferably, antimicrobial and antifogging films having a A/B/C/E structure. Most preferably, antimicrobial and antifogging films having a A/B/C/D/E structure. A multilayer structure (having at least an skin layer (A) having antifogging and antimicrobial properties/a core layer (C)/an outer layer (E) structure) for semi and biaxially oriented polyolefin based antifogging films having advantageous properties as compared with known and commercial films such as low values of haze, high values of sheen, lower longitudinal and transverse shrinkage, which provides high dimensional stability, and excellent antifogging and antimicrobial properties. Preferably the skin layer (A), having antifogging and antimicrobial properties, is electrical corona or flame treated. Electrical corona or flame treatment of the outer layer (E) may enhance ink anchorage and increase the printability of this layer. Preferably, the films comprise an inner (B) layer between the skin layer (A) and the core layer (C). Preferably, the films may comprise a second inner (D) layer between the outer (E) layer and the core layer (C). | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application based on U.S. patent application Ser. No. 10/923,972, filed Aug. 23, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the marking of storm drains to alert members of the public to the dangers in dumping detrimental materials into waterways. More specifically, the invention relates to a tamper-resistant marker for this purpose and to a method of mounting the marker.
[0004] 2. Description of the Prior Art
[0005] The U. S. Environmental Protection Agency (EPA) has directed the states to develop programs to educate the public about the dangers to the environment when materials that are harmful to the health and safety of living organisms are dumped into streets and driveways, eventually to be washed to storm drains to enter rivers, streams, and other waterways and, possibly, our drinking water system.
[0006] The education program includes the marking of storm drains which lead from roadways and ultimately to waterways. Currently, several methods are used to carry out this marking.
[0007] Firstly, stencils have been commonly used to apply a warning message to the surface of concrete or asphalt near the storm drain. However, the paints used typically weather poorly and have to be redone every few years. The spray painting itself is time consuming, and cannot be done in wet or cold weather, or in windy conditions. Moreover, the paint vapors are potentially harmful to the user. The resulting prints are messy, and leave a message less clear than desirable.
[0008] Alternatively, ceramic tile markers, which have been screen-printed with an appropriate message and glazed, may be applied with adhesives and cemented in place. Ceramic tile markers, however, are easy to crack in use and are expensive. Flat cast or metal markers have also been used in the past. These have good life expectancy, but are expensive to manufacture and difficult to read. Because of their flat backs, they often fail to adhere to the adhesives.
[0009] Finally, plastic domed markers are most often used to identify storm drains. They are made of a base material, such as vinyl or polycarbonate, screen-printed with an appropriate message, and die-cut into shape. The resulting blank is covered with a polyurethane coating having ultraviolet (UV) inhibitors to protect against damage caused by exposure to sunlight. This heavy, syrup-like coating flows to the edge of the blank and hardens. The resulting product has graphics under a clear plastic dome that thins near the edges. Adhesives, like liquid nails, may be used to apply the markers to various surfaces.
[0010] There are several problems associated with these plastic domed markers. Firstly, exposure to direct sunlight causes embrittlement in plastics. Secondly, daily temperature variations often cause the adhesive to fail on the undersurface of the marker because the flat vinyl surface is smooth and offers little bond to the adhesive. Finally, colorful, domed plastic markers are attractive and easily pried from the surfaces to which they are attached by vandals and others who like to collect them. A penknife or small screwdriver is all that is required for this purpose, as the plastic domed markers are flexible and can readily be peeled from the surface to which they are applied once an edge is exposed.
[0011] The present invention is directed toward these shortcomings of the prior art and provides a tamper-resistant marker which cannot be as readily removed from a surface as those of the prior art.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention is a tamper-resistant marker which comprises a blank made of metal sheet material. The blank is substantially flat and has a perimeter, two faces, and a flange extending therefrom about the perimeter in a direction substantially perpendicular to the faces. The blank also had indicia with raised portions on one of the two faces. The portions in question are raised in a direction opposite that of the flange. The areas between the raised portions may be painted to make the indicia more visible or legible, as the case may be.
[0013] As will be discussed below, the marker is mounted on a surface by cutting a groove thereinto having the shape of the flange extending around the perimeter of the blank. The flange resides in the groove below the level of the surface when mounted, making it difficult for a vandal to remove the marker.
[0014] The present invention also includes a method for manufacturing the tamper-resistant marker. The method comprises the steps of providing a blank of sheet metal, the blank having two faces and a perimeter, and of embossing indicia having raised portions onto one of the two faces of the blank. The method finally includes the step of forming a flange about the perimeter in a direction substantially perpendicular to the faces and in a direction opposite to that of the raised portions of the indicia.
[0015] Finally, the present invention includes a method of mounting the tamper-resistant marker on a surface. The method comprises the step of providing a marker having a substantially planar face and having a perimeter with a flange extending therefrom in a direction perpendicular to the face. The method also includes the step of cutting a groove into the surface onto which the marker is to be mounted. The groove conforms to the perimeter of the marker to accommodate the flange when the marker is installed on the surface.
[0016] Finally, an adhesive is applied onto the surface within the area defined by the groove, and the marker is pressed into the adhesive with the flange disposed in the groove.
[0017] The present invention will now be described in more complete detail with frequent reference being made to the figures identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a plan view of a marker of the present invention;
[0019] FIG. 2 is a cross sectional view of the marker taken as indicated in FIG. 1 ;
[0020] FIG. 3 is a perspective view of a hole saw having a coaxial drill;
[0021] FIG. 4 is a partly cross-sectional, partly perspective view of a marker when installed; and
[0022] FIG. 5 is a perspective view of an installed marker.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Turning now to these figures, FIG. 1 shows a plan view of a marker 10 of the variety used in the practice of the present invention. FIG. 2 is an enlarged cross section thereof taken as indicated in FIG. 1 .
[0024] The marker 10 is made of a metal, such as aluminum, brass or stainless steel, in heavy, 16-gauge (0.060-inch thick), blank sheets. Embossing dies form the flat blanks into deep three-dimensional disks or plates with raised copy, such as that on marker 10 . A high tonnage power press, rated at 400 tons, is used for this purpose. The embossing adds strength to the metal material, often equivalent to doubling its thickness.
[0025] After embossing, the oversized plate is placed upon a blanking die that forms a dome, drawing the sides of the blank rearward to form an approximately 0.125-inch-deep dish- or cup-like shape just before it cuts the round blanks. The flange 12 formed in this operation is shown in FIG. 2 , along with the embossed pattern 14 , which is what may be seen of the design shown in FIG. 1 when viewed in cross section.
[0026] The shaped blanks, which may, for example, be 4.0-inch-diameter disks, are then deburred by sanding the cut edges or tumbling the disk in an abrasive medium.
[0027] After cleaning, the disks are placed upon an anvil nest and an abrasive pad, scotchbrite or emery cloth is rotated upon the face, to give a prism-spin appearance that reflects light and gives a high-quality appearance to the disk. At the same time, this operation applies a fine, uniform circular scratch to the surface and background of the disk which improves the adhesion of paint to be applied thereon.
[0028] A baking enamel containing ultraviolet inhibitors is spray-painted onto the surface and, while still wet, the plate is placed upon a conveyor belt that transports the product under a series of rollers having a solvent-absorbing paper to remove the wet paint from the raised portions of the embossed surface leaving the background in a painted and contrasting color. Alternatively, the paint may be removed from the raised portions of the embossed surface after curing with an abrasive sanding disk.
[0029] The plate is then baked at high temperatures to cure the paint and make it hard.
[0030] Alternatively, the flat blanks may be screen-printed with a color-contrasting background prior to embossing in registration with the screen-printed background. One or more colors may be applied in this manner. The blank may also be baked prior to the embossing step in this alternative.
[0031] The resulting finished product is distinctive, easy to read, has a high-quality appearance and, when compared to any other existing storm drain marker, gives the appearance of a product of much higher cost. The product with embossed-copy permanence has a life expectancy of more than thirty years, that is, its three-dimensional copy will be readable for over thirty years, two or more times longer than other products in use today.
[0032] The marker 10 may be mounted onto a concrete or other surface in the following manner. The surface may be a flat or plane surface, and may also be the curved or flat surface of a utility pole of concrete, wood or fiberglass. Referring to FIG. 3 , a hole saw 20 having a diameter substantially equal to that of the marker 10 may be used to make a shallow circular groove into the surface on which the marker 10 is to be mounted. For centering purposes, and to accommodate a bolt for securing the marker 10 on the surface, the hole saw 20 has a drill 22 with a carbide bit 24 . Using a power tool, the hole saw 20 and carbide bit 24 can be used to drill a center hole, perhaps to a depth of 1.0 inch, in the center of a circular groove having a depth nominally in a range from 0.0625 to 0.125 inch into the concrete, asphalt or other surface where the marker 10 is to be mounted. The purpose of the circular groove is to accommodate the flange 12 on the marker 10 .
[0033] Upon completion of the drilling process, dust and chips are blown or brushed out. An adhesive or epoxy is then applied to fill the drilled hole and the area inside the circular groove. The marker 10 is then centered over the circular groove, lining up flange 12 therewith, and pressed down. As a consequence, the leading edge 14 or the flange 12 will be below the surface of the concrete or asphalt and the marker 10 will be embedded in the surface, presenting a much lower tripping hazard than other mounting methods.
[0034] FIG. 4 is a partly cross-sectional and partly perspective view of a marker 30 having a somewhat different design from marker 10 . The marker 30 has been installed in the manner described above. Flange 32 is disposed in circular groove 44 , and, as such, the leading edge 34 of the flange 32 is below the surface 40 of the concrete, asphalt or other material. An adhesive or epoxy 42 is used to hold the marker 30 to the surface 40 . Because the marker 30 , like marker 10 described above, has embossed areas which increase the surface area of the underside, the adhesive or epoxy 42 has increased area to bond both to the underside of the marker 30 and surface 40 . Also shown is the optional bolt 36 which is secured within hole 46 by adhesive or epoxy 42 .
[0035] FIG. 5 is a perspective view of marker 10 , which lacks a bolt 36 , installed on a surface 40 of concrete, asphalt or the like. Little adhesive or epoxy 42 may be seen around the perimeter of the marker 10 . Because the flange 12 of marker 10 is within a circular groove 44 into surface 40 , an implement, such as a screw driver or penknife, cannot reach below leading edge 14 to pry the marker 10 away. When embedded into concrete or asphalt in this manner, a snow plow scraping the top surface thereof will not dislodge the marker 10 as its flange 12 is firmly mounted below the level of the surface 40 .
[0036] Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the appended claims. | A tamper-resistant marker is formed of metal sheet material from a substantially planar blank thereof having a perimeter and two faces. The marker has a flange extending therefrom about the perimeter in a direction substantially perpendicular to the faces. The marker also has indicia with raised portions on one of the two faces, the raised portions being raised in a direction opposite to that of the flange. Methods of manufacturing the marker and of mounting it on a surface are also disclosed. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a vertical cavity surface emitting laser device comprising a vertical cavity surface emitting laser with a monolithically integrated photodiode arranged to measure the intensity of light emitted by said laser. The invention further relates to an optical sensor module for measuring distances and/or movements including such a vertical cavity surface emitting laser device.
BACKGROUND OF THE INVENTION
[0002] Vertical (extended) cavity surface emitting lasers (VCSEL/VECSEL) integrated with photodiodes are attractive devices for optical sensors based on self-mixing interference (SFI). These VCSEL integrated photodiodes (VIP) are the key component for the Twin-eye™ sensor from Philips Laser Sensors. In a further application of a VCSEL with integrated photodiode, the signal of the photodiode is used as a feedback signal for controlling or stabilizing the output power of the VCSEL.
[0003] Known designs of VCSEL devices with integrated photodiodes comprise an epitaxial layer stack forming the photodiode, which is arranged at the bottom of the VCSEL structure and is separated by a spacer layer from the bottom DBR (DBR: Distributed Bragg Reflector) of the VCSEL. In another design, the photodiode is integrated in the bottom DBR of the VCSEL. The latter design is disclosed for example in US 2003/0021322 A1, which describes a photodiode formed of an n-doped region, an intrinsic region and a p-doped region, which are integrated in the bottom DBR of the VCSEL. To this end, the bottom DBR is separated into a first, n-doped portion and a second, p-doped portion. The second p-doped portion forms the p-doped region of the photodiode, whereas the intrinsic region and the n-doped region are arranged between the two portions of the DBR. The VCSEL and the photodiode share a common electrode realized as an Ohmic n-contact at the n-doped region of the photodiode, which forms a spacer layer required in this design within the bottom DBR.
[0004] Although the photodiodes can be monolithically integrated with the VCSEL as shown above, the production costs are significantly higher than those of standard VCSELs. This is due to the required epitaxial layer stack which is much thicker for VCSELs with integrated photodiodes than in the case of simple VCSELs. Furthermore, in designs in which the p-doped region of the photodiode has to be electrically contacted, special fabrication steps are needed to provide an Ohmic contact to the p-doped layer of the integrated photodiode. The first drawback also applies to the device of US 2003/0021322, which requires a thick n-doped spacer layer within the bottom DBR. Such a thick spacer layer is undesirable because it increases the reactor growth time during fabrication and is almost as expensive as the simple mounting of a photodetector at the bottom side of the VCSEL instead of monolithically integrating the photodiode. The spacer layer also requires accurate thickness control during fabrication, such that mirror reflectivity and phase of the upper and lower portion of the bottom DBR match.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a vertical cavity surface emitting laser with monolithically integrated photodiode, which allows less complex fabrication in conjunction with a reduced thickness of the epitaxial layer stack compared with the prior art solutions.
[0006] The object is achieved with the vertical cavity surface emitting laser device and the optical sensor module according to claims 1 , 2 and 15 . Advantageous embodiments of the vertical surface emitting laser device are subject matter of the dependent claims or are described in the subsequent portions of the description and preferred embodiments.
[0007] The proposed vertical cavity surface emitting laser device comprises a vertical cavity surface emitting laser with a monolithically integrated photodiode arranged to measure the intensity of light emitted by said laser. The photodiode is formed of a layer sequence of a first n-doped region, a p-doped region, an intrinsic region and a second n-doped region of a semiconductor material. The photodiode and the laser share a common electrode which is realized as an Ohmic n-contact at said first n-doped region. Such a device can be fabricated on an n-doped substrate. An alternative solution is a device which is fabricated on a p-doped substrate. In this case, all dopings mentioned above and in the following description have to be inversed, i.e. n instead of p and p instead of n.
[0008] The term “vertical cavity surface emitting laser” in this patent application also includes so-called vertical external cavity surface emitting lasers (VECSEL). In the following, only for simplification the abbreviation VCSEL is used for both types of lasers.
[0009] With the use of a photodiode based on an epitaxial layer stack of n-p-i-n-doped semiconductor material, the design of the proposed device allows the use of a common electrode for the VCSEL cathode and the photodiode anode, realized as an Ohmic n-contact at the first n-doped region of the photodiode. Therefore, there is only one p-contact required for the electrical contacting of the device, thereby reducing the production complexity. Since the additional (first) n-doped layer of the photodiode is not required to fulfill the function of a thick spacer layer, the epitaxial layer stack forming the whole device can be manufactured thinner than the layer stacks of the prior art. All this results in a reduction of production costs and production time as well as production complexity compared to the prior art solutions.
[0010] The photodiode of the proposed device can be integrated in one of the DBRs of the VCSEL or formed as a continuation of the layer structure of the VCSEL. In the latter design, in which the VCSEL comprises a first layer structure including an active region being embedded between a p-doped DBR and a n-doped DBR, the photodiode is formed as a continuation of this first layer structure, such that the first n-doped region of the photodiode faces the n-doped DBR of the VCSEL.
[0011] Optimum results are achieved with a laser design in which the laser threshold current is less than 30% of the laser operating current. Furthermore, the bias of the photodiode should be chosen appropriately, for example at least about 0.4 V, depending on the design of the photodiode. The photodiode should be designed such that at low bias, e.g. 0.4 V, the intrinsic region is completely depleted or at least depleted sufficiently such that the detector capacitance is low enough and the detector responsivity is high enough for the desired operation.
[0012] The VCSEL of the proposed device has a design as known in the art with two layer structures embedding the active region and forming the two end mirrors of the laser cavity. These end mirrors are preferably distributed Bragg reflectors (DBR). The active region on the other hand is formed of a quantum-well structure. The VCSEL may be designed as a top or a bottom emitter.
[0013] When forming the layers of the photodiode as bulk layers, these bulk layers have a thickness of approximately 2 μm. Based on a typical growth rate for molecular beam epitaxy (MBE) of 500 nm/h, this means that it takes the MBI system more than one working day to form only those bulk layers. In order to reduce this manufacturing time, in an advantageous embodiment of the proposed device, the photodiode is based on thinner layers, preferably ≦500 nm thick, which are integrated in one of the DBRs of the VCSEL. In one of the embodiments such a photodiode is formed of a quantum-well structure. Quantum-wells are only a few nanometers thick and can easily be included in the epitaxial growth of the vertical cavity laser emission device. The same applies to the above thin layers. This will significantly reduce the time required for epitaxial growth of such a device.
[0014] Since thinner layers have less absorption than thick bulk material, the proposed photodiode having such thinner layers or quantum-wells is integrated in one of the DBRs of the VCSEL. The VCSEL in this case comprises a first layer structure including the active region being embedded between a first DBR and a second DBR, wherein the first n-doped region, the p-doped region, the intrinsic region and the second n-doped region of the photodiode are integrated in the second DBR. To this end, the second DBR may be formed of three portions, a first n-doped portion adjacent to the active region, a second p-doped portion and a third n-doped portion. The first n-doped region of the photodiode is then formed of the first n-doped portion of the second DBR. The p-doped region of the photodiode is formed of the second p-doped portion of the second DBR and the second n-doped region of the photodiode is formed of the third n-doped portion of the second DBR. The intrinsic region of the photodiode forming the absorbing layer is arranged between the second and the third portion of the second DBR. This second DBR may for example be the bottom DBR of a top emitting VCSEL. In order to integrate the above regions in the second DBR, the corresponding thin layers of this DBR must be adapted in their doping concentrations and material compositions in order to fulfill the function needed to form the photodiode. For example, in the case of a VCSEL emitting at 850 nm, the DBRs may be formed of layers of Al x Ga 1-x As, wherein x is chosen to achieve the desired high reflectivity. Without an integrated photodiode, the amount of Al is set higher than a minimum value in order to avoid light absorption in the layers. When integrating the photodiode, however, the amount of Al in the absorbing layer of the photodiode is lowered in order to achieve the desired absorption.
[0015] In order to control the relation between spontaneous light and stimulated light, which are detected by the photodiode, the longitudinal position of the absorbing quantum-well of the photodiode, i.e. of the intrinsic region, is carefully selected, preferably, to be in or close to the maximum of the standing wave pattern of the laser radiation in the laser cavity. The photodiode then much better detects stimulated emission compared to spontaneous emission.
[0016] As a further preferred measure to control or reduce the amount of spontaneous emission detected by the photodiode, one or more carefully doped quantum-wells or other thin doped layers are arranged between the intrinsic region and the p-doped region of the photodiode in order to create a spectral filter, preferably integrated in the p-doped portion of the second DBR. This spectral filter is designed to block or reduce the passage of spontaneous emission outside of the wavelength region of the stimulated emission, so that less spontaneous emission reaches the intrinsic region of the photodiode.
[0017] The proposed optical module comprises at least one such vertical cavity emitting laser device emitting a measuring beam which, when reflected by an object, re-enters the laser cavity and generates a self-mixing effect which is measured by the photodiode. Such an optical measuring module for measuring distances and/or movements also includes or is connected with appropriate signal processing circuitry which calculates the distance and/or movement based on the measuring signal of the photodiode. Such an optical module may be embedded in an input device or in an apparatus having such an input device included. Apparatuses wherein the input device can be used are for example a mouse for a desktop computer, a notebook computer, a mobile phone, a personal digital assistant (PDA) and a handheld game computer. The module can also be used in professional measuring apparatuses for measuring, for example, distance to an object or movement of the object, movement of a liquid and movement of particles embedded in a liquid. Generally, the invention may be used in any applications where the laser self-mixing effect can be used.
[0018] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The proposed vertical cavity surface emitting laser device is described in the following by way of examples and with reference to the accompanying Figures, without limiting the scope of protection as defined by the claims. The Figures show:
[0020] FIG. 1 a schematic view of a first embodiment of the proposed device;
[0021] FIG. 2 a schematic view of a second embodiment of the proposed device; and
[0022] FIG. 3 a schematic view of a third embodiment of the proposed device.
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] FIG. 1 is a schematic view of an exemplary design of the proposed device. The Figure shows a VCSEL structure 1 arranged on top of a layer sequence forming a photodiode 2 . The top emitting VCSEL comprises a layer structure including an active region 5 embedded between a lower DBR 3 and an upper DBR 4 . The upper DBR 4 is p-doped, the lower DBR 3 is n-doped. In such a top emitting VCSEL, the upper DBR is formed so as to be partly transmissive, for example with a reflectivity of 98% for the laser radiation generated in the active region 5 , enabling it to work as an outcoupling mirror. The upper and lower DBRs are typically composed of alternating high and low refractive index GaAs (high index) and AlAs (low index) layers. The GaAs layers have a low Al %, in the following referred to as Al x Ga 1-x As layers, such that the material band gap is above the photon energy. The lower DBR is designed so as to be highly reflective for the generated laser radiation, for example with a reflectivity of 99%. Nevertheless, a small portion of the laser radiation also passes the lower DBR and can be detected in the photodiode 2 arranged on this bottom side of the VCSEL.
[0024] The photodiode 2 is formed of a layer sequence of an upper n-doped Al x Ga 1-x As layer 6 , a p-doped Al x Ga 1-x As layer 7 , an intrinsic Al x Ga 1-x As layer 8 and a bottom n-doped Al x Ga 1-x As layer 9 . This design has the advantage that the cathode of the VCSEL and the anode of the photodiode 2 can share a common electrode, which is realized as an Ohmic n-contact 10 on top of the upper n-doped Al x Ga 1-x As layer 6 of the photodiode. A further Ohmic n-contact 11 which forms the cathode of the photodiode is arranged on the bottom portion of the bottom n-doped Al x Ga 1-x As layer 9 of the photodiode. The further required Ohmic p-contact 12 is arranged on top of the layer structure 1 forming the VCSEL as known in the art. Therefore, only one p-contact is required for the device, which helps to reduce the production complexity. The different layers of the photodiode may have the following thicknesses and doping concentrations, for example:
[0025] upper n-doped Al x Ga 1-x As layer 6 : thickness of approx. 2 μm; doping: 4.2*10 18 (1/cm 3 )
p-doped Al x Ga 1-x As layer 7 : thickness of approx. 2 μm; doping: 2.0*10 19 (1/cm 3 ) intrinsic Al x Ga 1-x As layer 8 : thickness of approx. 2 μm; no doping lower n-doped Al x Ga 1-x As layer 9 : thickness of approx. 650 μm forming the substrate; doping: 3.1*10 18 (1/cm 3 ).
[0029] The Ohmic contacts are preferably made of Ti/Pt/Au for the p-contact and Ge/Au/Ni/Au for the n-contacts.
[0030] FIG. 2 shows a further example of the proposed device in which the photodiode is formed of a quantum-well structure. In this example, the photodiode is integrated in the bottom DBR 3 a - 3 c of the VCSEL. The top DBR 4 and the active region as well as the Ohmic p-contact 12 forming the VCSEL anode are designed in a conventional manner. The bottom DBR 3 is separated into three portions. The upper portion 3 a is n-doped, an intermediate portion 3 b is p-doped and a bottom portion 3 c is n-doped. Between the intermediate portion 3 b and the bottom portion 3 c an absorbing quantum-well structure 14 is arranged forming the intrinsic region of the photodiode. With this design, the upper n-doped region, the p-doped region and the lower n-doped region of the n-p-i-n photodiode of the proposed device is formed by the layers of the bottom DBR. The upper n-doped region is formed by the upper n-doped portion 3 a of the bottom DBR. The p-doped region is formed by the intermediate p-doped portion of the bottom DBR and the lower n-doped region of the photodiode is formed by the n-doped bottom portion 3 c of the bottom DBR. Except for the absorbing quantum-well structure 14 , no additional layers have been added to the lower DBR 3 of this structure in order to set up the photodiode. This means that the epitaxial layer stack forming the device is approximately as thick as for standard VCSELs. There is no need to grow 6 μm or more of bulk material for the photodiode. This reduces the manufacturing time and costs. The Ohmic n-contact forming the cathode of the VCSEL and at the same time the anode of the photodiode is arranged at the upper n-doped portion 3 a of the lower DBR 3 which at the same time represents the upper n-doped region of the photodiode. The whole layer structure is grown on an n-doped substrate 13 to which at the bottom side the Ohmic n-contact for the cathode of the photodiode is attached.
[0031] FIG. 3 shows a further example of the proposed device, which is constructed similarly to the device of FIG. 2 . The only difference is an additional quantum-well or quantum-well structure 15 which is formed in the p-doped portion of the bottom DBR 3 , i.e. in the intermediate portion 3 b of this bottom DBR. This additional quantum-well structure 15 on top of the absorbing quantum-well structure 14 is designed to filter light propagating from the active region 5 towards the intrinsic region of the photodiode, such that stimulated emission of the laser can pass and spontaneous emission in wavelength ranges outside of the wavelength range of the stimulated emission is strongly reduced. With this additional filter quantum-well structure 15 , which is doped to avoid re-emission of absorbed light, the amount of spontaneous emission that is detected by the absorbing quantum-well 14 is reduced.
[0032] While the invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. The different embodiments described above and in the claims can also be combined. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure and the appended claims. For example, the VCSEL used can also be composed of other material layers or may be a bottom emitting laser as known in the art. Furthermore, the semiconductor laser may also be designed as a vertical extended cavity surface emitting laser (VECSEL). The number of layers in the layer stacks is not limited by the present invention. This number can be selected appropriately for the required optical properties of the layer stack.
[0033] In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The reference signs in the claims should not be construed as limiting the scope of these claims.
LIST OF REFERENCE SIGNS
[0000]
1 layer structure of VCSEL
2 layer sequence of photodiode
3 lower DBR
3 a top portion of bottom DBR
3 b intermediate portion of bottom DBR
3 c bottom portion of bottom DBR
4 upper DBR
5 active region
6 upper n-doped Al x Ga 1-x As layer
7 p-doped Al x Ga 1-x As layer
8 intrinsic Al x Ga 1-x As layer
9 lower n-doped Al x Ga 1-x As layer
10 Ohmic n-contact
11 Ohmic n-contact
12 Ohmic p-contact
13 n-doped substrate
14 absorbing quantum-well
15 filter quantum-well | The present invention relates to a vertical cavity surface emitting laser device comprising a VCSEL with a monolithically integrated photodiode. The photodiode ( 2 ) is formed of a layer sequence of a first n-doped region ( 6 ), a p-doped region ( 7 ), an intrinsic region ( 8 ) and a second n-doped region ( 9 ) of a semiconductor material. The photodiode ( 2 ) and the laser share a common electrode, which is realized as an Ohmic n-contact ( 10 ) at said first n-doped region ( 6 ). The proposed device allows less complex manufacturing, resulting in lower manufacturing costs. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
Co-owned U.S. patent application Ser. No. 11/789,618, filed Apr. 25, 2007 is made of record.
BACKGROUND
1. Field
The embodiments relate to labeling methods, webs of fabric labels and fabric label arrays.
2. Brief Description of the Prior Art
Prior art is disclosed in connection with FIGS. 31 through 34 of the present application and in the following U.S. Pat. Nos. 5,583,489 and 7,125,182.
Fabric labels applied to garments may carry printed washing and/or dry cleaning instructions, warranty information, country-of-origin, fabric content, size information and the manufacturer's and/or the merchant's logo. Generally, the label is sewn or heat sealed into or onto the garment and the outer side of the label is printed right-side-up and the underside of the label is printed right-side down. If a set of one or more separate labels is intended to be used on a particular garment, there exists the possibility that some of the labels from one set may be interchanged with those of another set and/or that the labels of one set may not be correctly oriented with respect to each other.
SUMMARY
According to the disclosed embodiments, a fabric web of labels is prepared by providing one or more longitudinally extending lines of partial severing to frangibly connect one or more longitudinally extending parallel zones or regions of the web. If desired, the web can also be weakened or partially severed transversely to provide fold lines. The web, usually in roll form, can be loaded into a printer and the desired information can be printed on the outer or upper side of the web and on the underside or lower side of the web. A set or array of connected labels can be severed from the web and can be stacked or otherwise arranged until ready to be used. The connected labels can be folded and attached, for example, sewn or heat sealed onto a garment. Because the labels remain connected even when they are being attached to the garment, there is no possibility that a label from one set can be mismatched with the label of any other set or that the labels can be mis-oriented relative to each other. This use of multiple labels in an array or set or composite on a garment is particularly useful when it is desired to provide the same garment related information on the garment in different languages. Once the label array has been attached to the garment it is a simple matter to break the frangible connection between labels manually when it is desired to read the information on the underside of the outermost label or on an underlying label. Especially the label arrays with three or four labels have substantial information-carrying capacity, and this is valuable in the event the same information is required to be printed in two or more different languages on the same label array. The printing of the same information of, for example, eight languages on eight sides of four connected labels is contemplated.
A specific embodiment of a labeling method comprises some or all of the steps of providing a longitudinally extending web of printable fabric label material having opposite sides or faces and bounded by at least one longitudinally extending frangible line of partial severing spaced between the side edges to provide repetitive sets of at least two labels, and printing information on one face of the web on all or most of the labels of each set and on the other face of the web on at least one of the labels of each set, the labels being capable of undergoing repeated washings and/or dry cleanings, severing the web between along transverse lines between sets to provide two or more printed labels frangibly connected at the partial severing, folding the labels relative to each other to provide a folded label array of at least two frangibly connected, printed labels, attaching the label array to a garment, and separating at least two labels of the array at the partial severing after the array has been attached to the garment.
A specific embodiment of a labeling method comprises some or all of the steps of providing a label array of at least three printed labels connected along at least two frangible lines, the printed labels being capable of undergoing repeated washings and/or dry cleanings, folding the labels along the frangible lines into face-to-face relationship, attaching the printed label array of frangibly connected labels to a garment, and thereafter separating at least some of the labels from each other along the frangible lines.
A specific embodiment of a labeling method comprises some or all of the steps of printing an array of at least two generally planar, frangibly connected, labels in a single printer, folding the labels relative to each other into a folded array, attaching the folded array to a garment and separating the labels from each other along their frangible connection.
In the event a manufacturer or merchant or consumer desires to selectively remove one or more labels of the array in any of the embodiments, the label or labels can be cut off from the array. For example, in the event the array contains four labels with, for example, care instructions in a different language on each side of the label, one or more labels can be cut off to remove two of the languages per label. In another example, a manufacturer may apply one logo to one label and another logo to another label of the array and selectively remove the label carrying the unwanted logo; for example, if a manufacture intends to sell the same product to two different merchants, the manufacturer could apply a different logo to different labels of the array and selectively cut off one label as needed. This will enable the manufacturer to produce or hold a single inventory for both merchants. Even if one or less than all of the labels are cut off, the remaining label or labels could carry the legally required care instructions. If desired, a cut line comprising printing, weaving or perforating to indicate where the label or labels should be cut to avoid damaging the garment can be applied directly to the label or labels adjacent the place where the array is attached to a garment. In addition, a scissor symbol can be applied adjacent the cut to further visually show where the label can be severed from the array, and in this connection reference is made to U.S. Pat. No. 5,583,489. Alternatively, any one or more of the labels could carry a bar code and/or a radio frequency identification (RFID) or electronic article surveillance (EAS) transponder, which could be removed by the merchant or customer by cutting that label from the array, if desired.
BRIEF DESCRIPTION OF THE DIAGRAMMATIC DRAWINGS
FIG. 1 is a simplified side elevational view of a printer wherein the lower face of a web is being printed by a print head and the upper face of the web is being printed by another print head prior to the web being severed;
FIG. 2 is a top plan view of an embodiment of a web that has been printed in the printer such as the printer depicted in FIG. 1 ;
FIG. 3 is a bottom plan view of the web shown in FIG. 2 ;
FIG. 4 is a top plan view showing one label array of FIGS. 2 and 3 that has been severed from the remainder of the web;
FIG. 5 is a bottom plan view of the label array of FIG. 4 ;
FIG. 6 is a pictorial view showing the label array as having been folded about a line of partial severing or weakening and partially folded about another fold line of partial severing or weakening;
FIG. 7 is a pictorial view of the label array attached to an article such as a garment;
FIG. 8 is another pictorial view of the label array attached to the garment;
FIG. 9 is a front elevational view of the attached label array shown in FIGS. 7 and 8 for example showing side 1 of the outermost label;
FIG. 10 is a view similar to FIG. 9 , but showing the outermost label folded up to expose its side 2 and side 3 of the first underlying label;
FIG. 11 is a view similar to FIGS. 9 and 10 , but showing the outermost label and the first underlying label folded up to expose side 4 of the first underlying label and side 5 of the second underlying label;
FIG. 12 is a view similar to FIGS. 9 through 11 with the outermost label and the two underlying labels folded up to expose side 6 of the underlying labels and side 7 of the third underlying label;
FIG. 13 is a view similar to FIGS. 9 through 12 with all the labels folded up to expose side 8 of the third underlying label;
FIG. 14 is a top plan view of an alternative embodiment of a web that has been printed in the printer of FIG. 1 ;
FIG. 15 is a bottom plan view of the web shown in FIG. 14 ;
FIG. 16 is a top plan view of one label array of FIGS. 14 and 15 that has been severed from the remainder of the web;
FIG. 17 is a bottom plan view of the label array of FIG. 16 ;
FIG. 18 is an enlarged pictorial view of the label array shown in FIGS. 16 and 17 , partially folded;
FIG. 19 is a view of a completely folded label array as viewed toward the right side of FIG. 18 ;
FIG. 20 is a front elevational view of the label array shown in FIGS. 16 through 19 showing side 1 of the label array;
FIG. 21 is a view similar to FIG. 20 , but showing the outermost label folded up to expose its side 2 and side 3 of the underlying label;
FIG. 22 is a view similar to FIGS. 20 and 21 , but showing the outermost label and the underlying label folded up to expose side 4 of the underlying label;
FIG. 23 is a top elevational view of yet another embodiment of a web that has been printed in a printer such as the printer depicted in FIG. 1 ;
FIG. 24 is a bottom plan view of the web shown in FIG. 23 ;
FIG. 25 is a developing view showing the manner in which the label array is folded to form face-to-face labels that are to be attached to a garment;
FIG. 26 is a front elevational view of the label array shown in FIGS. 23 through 25 , showing side 1 of the label array;
FIG. 27 is a view similar to FIG. 26 , but showing the outermost label folded up to expose its side 2 and side 3 of the underlying label;
FIG. 28 is a view similar to FIGS. 26 and 27 , but showing the outermost and the first underlying labels as folded up to expose side 4 of the first underlying label and side 5 of the second underlying label;
FIG. 29 is a view similar to FIGS. 26 through 28 , but showing the outermost label and the first and second underlying labels folded up to expose side 6 of the second-underlying label;
FIG. 30 is an alternative arrangement for folding a label web similar to the one shown in FIGS. 23 and 24 ;
FIG. 31 is a pictorial view of a prior art label array partially folded and showing sides 1 and 3 ;
FIG. 32 is a front elevational view of the prior art label array of FIG. 31 sewn onto a garment;
FIG. 33 is a view similar to FIG. 32 , but showing the outermost label folded up to expose side 2 of the outermost label and side 3 of the underlying label; and
FIG. 34 is a view similar to FIGS. 32 and 33 , but showing both labels folded up to expose side 4 of the underlying label.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference initially to FIG. 1 which applies to the embodiments of FIGS. 2 through 30 , there is shown a thermal printer generally indicated at 50 including thermal print heads 51 and 52 cooperable at printing positions with respective platen rolls 53 and 54 to print on lower and upper side or faces L and U respectively of a web generally indicated at W. Ink ribbons 55 and 56 drawn across respective print heads 51 and 52 are used to transfer ink to the respective lower and upper faces L and U of the web W. Cooperating knives 57 and 58 are used to cut sets or arrays of labels from the web W. As shown, the web W moves in the direction of arrow 59 and the ink ribbons 55 and 56 move in the direction of arrows 60 and 61 during printing. Although a thermal printer 50 is illustrated, any other suitable printer such as an ink jet printer, a flexographic printer or an offset printer can be used instead of a thermal printer. A commercial embodiment of a printer that can be used is disclosed in U.S. Pat. No. 7,125,182.
With reference to the embodiment of FIGS. 2 through 13 , and initially to FIGS. 2 and 3 , there is shown a web W of printable fabric which have been printed with information I. Throughout, information that is printed right-side-up is indicated with an up arrow or an inverted “V” and information which is printed right-side-down is indicated with a down arrow or a “V”. Information I which is printed right-side-up can be read in the usual way from top to bottom, and information I which is printed right-side-down can best be read from top-to-bottom when it is turned upside down.
The longitudinally extending web W is shown to have spaced, preferably parallel, longitudinally extending side edges 62 and 63 . Longitudinally spaced transverse lines of weakening or partial severing generally indicated at 64 are preferably made at equally spaced apart intervals and preferably midway between adjacent lines indicated at 65 where severing can occur, although as shown in FIGS. 2 and 3 there is no severing of the web W along those lines. However, the lines 65 are nevertheless referred to herein as lines of severing. Partial severing or weakening 64 can be made by perforation cuts as shown, or by scoring, embossing, crushing or any other upsetting of the fabric which can make it easier to fold the fabric. The lines 65 show where the web W can be cut by knives 57 and 58 for example. There could be registration elements along the cut lines, but in the present embodiment it is preferred to have printed registration elements 66 at the lines of weakening 64 . The registration elements 66 can be cutouts or holes as shown or they can be printed marks or notches, for example.
FIGS. 2 and 3 each show two complete sets or arrays generally indicated at 76 . FIG. 2 shows the upper side or face U and FIG. 3 shows the lower side or under face L of the web W. The areas between adjacent lines of severing 65 indicate one label set or array 67 . A longitudinally line of partial severing or weakening 68 is shown midway between side edges 62 and 63 , as is preferred. The line of weakening 68 may be comprised of uncut or frangible or severably portions 68 a and completely cut portions 68 b and 68 c between two side-by-side pairs of labels of the array 67 . In that the lines of weakening 64 are shown midway between cut lines 65 , as is preferred, each label set or array has four equal size labels 69 , 70 , 71 and 72 . However, the lines of weakening 64 can be at other than midway between adjacent cut lines 65 , if desired. Accordingly, the labels of the array would be of different sizes. With reference to FIG. 2 , labels 67 through 72 on the upper face U are shown to have sides: 1 , 4 , inverted 5 and inverted 8 . With reference to FIG. 3 , the labels 69 through 72 on the lower face L are shown to have sides: inverted 2 , inverted 3 , 6 and 7 .
FIGS. 4 and 5 show one label set or array 67 as having been cut from the web W. The cut ends of an array are indicated at 73 and 74 .
FIG. 6 shows the label array 67 partial folded. The array 67 is first folded about line of weakening 64 and thereafter about line of weakening 68 . The fully folded array 67 shown in FIGS. 7 and 8 attached to an article such as a fabric garment G. FIG. 7 is viewed generally from the left side of FIG. 6 , while FIG. 8 is viewed from the right side of FIG. 6 . The label array 67 can be attached by sewing or stitching through the array 67 and the garment G as indicated at 75 or adhesively.
FIGS. 9 through 13 show the manner or organization of the printing on the upper and lower faces or sides U and L respectively of the folded array 67 , so that when the array 67 is folded all sides 1 through 8 are readable from top-to-bottom. In FIG. 9 , side 1 of the outermost label 69 is readable from top-to-bottom. In FIG. 10 , once frangible or severable portions 68 a between the labels 69 and 72 have been fractured or broken, as by using a finger inserted between adjacent labels 69 and 70 , the label 69 can be folded up to the position shown so that both the information on side 2 of label 69 and side 3 of label 70 can be read from top-to-bottom. In FIG. 11 , once the frangible portions 68 a between side edges of the labels 70 and 71 has been broken, the label 71 can be folded up as shown and both the information on side 4 of the label 70 and the information on side 5 of the label 71 can be read from top-to-bottom. In FIG. 12 , the label 71 can be folded up and the side 6 of the label 71 and the side 7 of the label 72 can be read from top-to-bottom. In FIG. 13 , once the label 72 has been folded up, the side 8 of the label 72 can be read from top-to-bottom. It can be seen that the label array 67 can be cut from the web W and folded to make four labels 69 through 72 with eight sides 1 through 8 , and yet all the labels are readable from top-to-bottom. In order to achieve all the benefits of this arrangement some of the printing of information I along the web W must extend in one direction and other of the information must extend in the opposite direction on both faces U and L. Thus, when the array 67 is attached to an article such as a garment G, all the information I can be read from top-to-bottom. In that all the labels 69 through 72 of the array 67 preferably remain connected at least until the array 67 is ready to be attached to the garment G, there cannot be a mixup or interchange of the labels 69 through 72 that belong to one set or array 67 with those labels that belong to another set, nor can there be a mixup as to the correct orientation of the various labels 69 through 72 with respect to each other. The label web of each of the embodiments disclosed herein is preferably comprised of a coated, woven or non-woven, polyester or acetate or other synthetic material that can be readily broken or cut manually at the frangible portions 68 a for example. Thus, it is a simple matter to tear the labels 69 through 72 for example, apart should it be desired to read information on the underside of the outermost label 69 or any of the first, second and third underlying labels. It should be noted that each label preferably has at least one frangible portion connecting it to an adjacent label transverse thereto, but more than two frangible portions per label can be used. Also, it is not necessary that all the labels in any disclosed array, such as the array 67 , need be printed on both sides.
FIGS. 2 , 4 and 6 show indicia preferably printed on the array 67 in the form of an “A” and a “B” with respective arrows. The letters “A” and “B” are a guide, reference or aid to the person who folds the array 67 to firstly fold the array 67 about line of weakening 64 and to secondly fold the array 67 about the line of weakening or fold line 68 . These indicia are meaningful to the person who folds the array 67 to show the sequence in which the array is to be folded but are irrelevant to the user of the garment. Other indicia such as a “1” and a “2” could be used instead of “A” and “B” or the indicia would be in other languages. The indicia are omitted from small figures, namely, FIGS. 9 through 13 for clarity. Such indicia can also be used in connection with the embodiment of FIGS. 23 through 29 , and in the embodiment of FIG. 30 for the same purpose, if desired.
The embodiment of FIGS. 14 through 22 comprises a web generally indicated at Wa that can be cut into label arrays along cut lines 65 a . The cut lines 65 a are shown to pass through registration elements 66 a which can be holes like the registration elements 66 . The web Wa has side edges 62 a and 63 a . A longitudinally extending frangible line of partial severing or weakening generally indicated at 68 ′ is shown to be comprised of cut lines 68 b ′ and 68 c ′ spaced by uncut frangible or severably portions or lands 68 a ″. Upper face U of each label array 67 a has sides 1 and 4 of labels 76 and 77 and lower face L of each label array 67 a has sides 2 and 3 of labels 76 and 77 . As is preferred, the frangible line of weakening 68 ′ is midway between side edges 62 a and 63 a so that labels 76 and 77 are of equal size.
FIGS. 16 and 17 show the label array 67 a as having been severed from the web Wa. The cuts at the cut lines 65 a form ends 78 and 79 . FIG. 18 shows the label array or composite label 67 a as partially folded about frangible line of weakening 68 ′ to partially expose side 3 of label 77 . FIG. 19 shows the label array attached to the garment G, as by stitching 75 ′ along line 75 ″.
FIGS. 20 through 22 show that the disclosed arrangement results in all of the sides 1 through 4 of the label array 67 a being readable from top-to-bottom once the labels 76 and 77 are separated along line 68 ′. In FIG. 20 , the information I on side 1 of the outer label 76 is readable from top-to-bottom. In FIG. 21 , the outer label 76 has been folded up to expose printed information I on side 2 and printed information I on side 3 of the label 77 . In FIG. 22 , both labels 76 and 77 have been folded up to expose information I on side 4 of the label 77 .
In the embodiment of FIGS. 23 through 29 , there is disclosed a web Wb having spaced apart parallel side edges 80 and 81 extending in the longitudinal direction. The web Wb can have registration elements 82 at longitudinally spaced locations. The registration elements 82 are shown to lie along the lines 83 at which complete severing can occur. There are two longitudinally extending frangible, parallel lines of partial severing generally indicated at 84 and 85 spaced between the side edges 80 and 81 . The line 84 and the side edge 80 , the lines 84 and 85 , and the line 85 and the side edge 81 are preferably equally spaced and parallel so that the labels 89 , 90 and 91 have the same width and size. The lines 84 and 85 have respective completely severed portions 84 b and 84 c and 85 b and 85 c . When the web Wb is cut or severed along lines 83 , the cut makes the ends 86 and 87 of the label array 88 as shown in FIG. 26 for example. Each label array 88 is comprised of connected labels 89 , 90 and 91 . When a label array or set 88 has been cut from the web Wb, the label 90 is folded about line 84 relative to the label 89 in the direction of arrow 92 until the labels 89 and 90 are face-to-face. Thereafter, the label 91 is folded about line 85 relative to the label 89 in the direction of arrow 93 until the label 91 is face-to-face with the label 90 . In this folded condition, the label array 88 can be attached to an article such as a garment G as shown in FIG. 26 , for example, as for example by sewing 94 . When the frangible or severable portions or lands 84 a and 85 a are torn or cut, then the label 89 can be folded up to expose side 2 of the label 89 and side 3 of the label 90 as shown in FIG. 27 . When the label 90 is also folded up as shown in FIG. 28 , the side 4 of the label 90 and the side 5 of the label 91 are exposed. When also the label 91 is folded up as shown in FIG. 29 , the side 6 of the label 29 is exposed.
The embodiment of FIG. 30 is the same as the embodiment of FIGS. 23 through 29 , except that the label array 97 is folded according to an inverted “Z” pattern as shown in FIG. 30 and also the arrangement of the printing on labels 94 , 95 and 96 of the label array 97 needs to be different than in the embodiment of FIGS. 23 through 29 so that all of the information I is readable from top-to-bottom. In folding the label array 97 , the label 95 can first be folded about line of weakening 84 relative to the label 94 until the label 95 is face-to-face and parallel to the label 94 . Second, the label 96 can be folded about line of weakening 85 until the label 96 is face-to-face and parallel to the label 95 . When thus folded, the label array 97 can be attached to the garment G.
With reference to the prior art of FIGS. 31 through 34 , a long label array 100 is folded about a fold line 101 to provide labels 102 and 103 . Alternatively, the labels 101 and 103 can be separate but nevertheless sewn to the garment G as indicated at 104 . Alternatively, more than two folded labels 102 and 103 or more than two separate labels can be sewn together onto the garment, but there is no way to assure that separate labels are correctly associated or oriented.
FIG. 33 shows side 2 of label 102 and side 3 of label 103 exposed by folding the label 102 up. FIG. 34 shows both labels 102 and 103 folded up to expose side 4 of the label 103 .
In the various embodiments, the frangible lines 68 , 68 a ′ 68 ′, 84 and 85 are preferably perpendicular to respective lines 65 , 65 a , and 83 . All the frangible lines 68 , 68 a ′ 68 ′, 84 and 85 are preferably parallel to respective side edges 62 , 63 , 62 a , 63 a , 80 and 81 . The lines 65 , 65 a and 83 of each web are preferably parallel to each other.
In all the disclosed embodiments, the labels are capable of undergoing repeated washings and/or dry cleanings.
Side edges of the webs W, Wa and Wb are preferably straight. The labels of each set or array are preferably rectangular and preferably the same size, and preferably longer in the direction away from the place the label array is attached, however, the labels can be of different sizes.
While the frangible or severable portions of the various disclosed embodiments are severable by hand, alternatively a knife blade could be used, if desired.
Other embodiments and modifications of the invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims. | There are disclosed several embodiments of label sets or arrays having a substantial capacity for printed information while maintaining all the labels of the array associated and properly oriented with respect to each other, wherein all the labels of each set or array can be printed in a printer. The labels of the array are preferably printed in transverse rows across a label web to increase the number of labels that can be carried on a roll. | 3 |
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/156,323 filed Feb. 27, 2009.
TECHNICAL FIELD OF THE INVENTION
[0002] This disclosure relates generally to oral appliances, and more particularly to an apparatus and method for coupling an oral appliance to a gas delivery device.
BACKGROUND OF THE INVENTION
[0003] Many people experience breathing problems, which may result in difficulty sleeping, in snoring, or in other more serious conditions such as obstructive sleep apnea. One treatment for such breathing disorders involves the use of devices that are inserted into a user's mouth for extending the user's lower jaw forward. These devices open the airway (i.e., breathing passageway) more fully to allow easier breathing through the nose and mouth. Certain of these devices include upper and lower arches that are connected together using a mechanism that may be adjusted to pull the lower arch, and thus the user's lower jaw, forward to open the airway more fully. Certain devices include masks that deliver air, oxygen, or other gases to a user through their mouth and/or nasal passages.
SUMMARY OF THE INVENTION
[0004] According to one embodiment, an apparatus for improved breathing includes an oral appliance, a gas delivery device, and a coupler. The gas delivery device is configured to direct gas to the breathing passages of a user. The coupler includes a swivel, a clamp, and a post with two arms. The clamp is configured to engage the post and to slide along the length of the post. The clamp is also configured to position and secure the swivel to define its position and orientation relative to the post. The gas delivery device is coupled to the oral appliance utilizing the swivel.
[0005] According to one embodiment, an apparatus for coupling an oral appliance to a gas delivery device includes a post, a swivel, and first and second opposing clamps. The post includes a base configured to couple to the oral appliance; a first arm extending from the base and defining a channel extending along a portion of the first arm; and a second arm extending from the base, extending substantially parallel to the first arm, the second arm defining a channel extending along a portion of the second arm. The swivel is substantially spherical and is configured to position the gas delivery device. The first clamp is configured to engage and slide along the channel defined by the first arm and the second clamp is configured to engage and slide along the channel defined by the second arm. The first and second opposing clamps are together configured to position and secure the location and orientation of the swivel relative to the post. In certain embodiments, the first and second opposing clamps may include protrusions shaped to engage and slide along the channels defined by the first and second arms.
[0006] According to one embodiment, a method for coupling an oral appliance to a gas delivery device includes coupling the gas delivery device to the oral appliance using a coupler. The coupler includes a post, a first clamp, a second clamp, and a substantially spherical swivel. The post includes a base, a first arm extending from the base, a second arm extending from the base. The first arm defines a first channel extending along a portion of the first arm. The second arm extends substantially parallel to the first arm and defines a second channel extending along a portion of the second arm. The first clamp is configured to engage and slide along the first channel and the second clamp is configured to engage and slide along the second channel. The method includes positioning the gas delivery device relative to the oral appliance. Positioning the gas delivery device includes adjusting the location of the gas delivery device along the first and second channels utilizing the first and second clamps. Positioning the gas delivery device also includes adjusting the orientation of the gas delivery device utilizing the swivel. The method further includes securing the position of the gas delivery device relative to the oral appliance utilizing the first and second clamps.
[0007] Certain embodiments of the present invention may provide one or more technical advantages For example, certain embodiments may provide for precise positioning of a gas delivery device. As another example, certain embodiments may provide for coupling a gas delivery device to an oral appliance in a manner that allows for positioning of the gas delivery device as well as adjustment of the oral appliance. Certain embodiments may provide some, none, or all of these advantages. Certain embodiments may provide one or more other technical advantages, one or more of which may be readily apparent to those skilled in the art from the figures, description, and claims included herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Reference is now made to the following description taken in conjunction with the accompanying drawings, wherein like reference numbers represent like parts, in which:
[0009] FIG. 1 illustrates an example oral appliance for improving a user's breathing;
[0010] FIGS. 2A through 5B illustrate an example adjustment mechanism;
[0011] FIGS. 6A through 6C illustrate example hooks with varying lengths, for use with an example adjustment mechanism;
[0012] FIGS. 7A through 7C illustrate example receivers with varying dimensions;
[0013] FIGS. 8A through 10 illustrate an example adjustment mechanism utilizing an example extender;
[0014] FIGS. 11A and 11B illustrate an example extender;
[0015] FIGS. 12A and 12B illustrate example receivers;
[0016] FIGS. 13 through 16 illustrate an example adjustment mechanism utilizing an example adjustment key;
[0017] FIGS. 17 through 19B illustrate an example adjustment mechanism utilizing an example extension post;
[0018] FIGS. 20A through 20B illustrate transverse cross-sectional views of example extension posts; and
[0019] FIGS. 21 through 23 illustrate an example housing, for use with an example adjustment mechanism;
[0020] FIGS. 24A through 25C illustrate example receivers, for use with an example housing;
[0021] FIG. 26 illustrates an example coupler, an example gas delivery device, and an example body;
[0022] FIGS. 27A-D illustrate various examples of a post;
[0023] FIGS. 28A-29D illustrate example clamps, for use with an example post;
[0024] FIGS. 30A-D illustrate examples of a swivel, for use with an example post;
[0025] FIGS. 31A-B illustrate examples of a post, for use with an example oral appliance;
[0026] FIG. 32 illustrates an example method of improving a user's breathing; and
[0027] FIG. 33 illustrates an example method of coupling a gas delivery device and an oral appliance.
DETAILED DESCRIPTION OF THE INVENTION
[0028] FIG. 1 illustrates an example oral appliance 100 coupled to an example gas delivery device 110 . In general, oral appliance 100 may be used to treat sleep disordered breathing, such as snoring or obstructive sleep apnea, through forward adjustment of the user's lower jaw relative to the upper jaw. This forward adjustment opens the breathing passage more fully and facilitates improved breathing through the user's nose and mouth. In certain embodiments, oral appliance 100 remains entirely within the user's mouth and surfaces of oral appliance 100 that may contact the interior of the user's mouth are smooth to prevent injury or discomfort. Although not intended to be exclusive, example oral appliances are described in one or more of U.S. Pat. Nos. 5,427,117; 5,566,683; 5,755,219; 6,516,805; 5,954,048; 5,983,892; 6,374,824; 6,325,064; 6,247,926; and 6,405,729 each of which is incorporated herein by reference.
[0029] Oral appliance 100 includes an upper arch 102 configured to receive at least some of a user's upper teeth, a lower arch 104 configured to receive at least some of the user's lower teeth, and an adjustment mechanism 10 . Upper arch 102 and lower arch 104 may include molds of at least some of the user's upper and lower teeth, respectively, for improved performance and comfort. Adjustment mechanism 10 couples lower arch 104 to upper arch 102 and may be adjusted to pull lower arch 104 forward to facilitate improved breathing. In certain embodiments, adjustment mechanism 10 may also vertically position lower arch 104 relative to upper arch 102 to determine the opening of the user's lower jaw. The components of adjustment mechanism 10 may be made from any suitable material such as, for example, a biocompatible metal or hard plastic.
[0030] Gas delivery device 110 may fit over the patient's nose and other portions of the patient's face or may be nasal inserts or nose pillows to direct gas directly into the patient's nasal passages. Although not intended to be exclusive, example gas delivery devices are described in one or more of U.S. Patent Publication Nos. 2007/0006879; 2008/0006273; and 2008/0060648 each of which is incorporated herein by reference. Gas delivery device 110 may be coupled to a system for providing one or more gases. For example, gas delivery device 110 may be coupled to a positive air pressure device, such as a constant positive air pressure (CPAP) system or bi-level positive air pressure (BiPAP) system. Although CPAP and BiPAP are used as examples, other systems for delivering air or other gases at constant or varying pressure may be used. Such systems may deliver any breathable gas, such as air or oxygen. It should be understood that the term “gas” is intended to include air.
[0031] Coupler 120 may couple oral appliance 100 to gas delivery device 110 . Coupler 120 allows for adjustable movement of gas delivery device 110 relative to oral appliance 100 in multiple directions. In particular embodiments, coupler 120 allows gas delivery device 110 to be adjusted along a substantially anterior-posterior axis and rotated about multiple axes.
[0032] FIGS. 2A through 5B illustrate an example adjustment mechanism 10 for use with oral appliance 100 . In certain embodiments, adjustment mechanism 10 may include body 12 , hook 28 , adjustor 36 , and receiver 50 . Body 12 may be integrated into or coupled to upper arch 102 . Body 12 may include a rear plate 14 , one or more rear fasteners 16 , a front plate 18 , and one or more front fasteners 20 . In certain embodiments, body 12 may further include one or more fastener passages 22 , one or more guides 32 , and one or more adjustment indicators 44 . Hook 28 may include flange 30 , adjustor passage 34 , and arm 46 .
[0033] When assembled, rear plate 14 may be coupled to body 12 through the use of one or more fasteners 16 . Fasteners 16 may be threaded fasteners, pins, or any other appropriate fastener to couple rear plate 14 to body 12 . Hook 28 may be coupled to body 12 through the use of one or more flanges 30 engaged within the one or more guides 32 . Adjustor 36 may include pin 38 and opening 42 . Opening 42 may be square, hexagonal, or any other appropriate shape to allow for a rotational force to be applied to adjustor 36 . Adjustor 36 may be positioned within adjustor passage 34 of hook 28 and pin 38 may be aligned with and inserted into hole 40 of rear plate 14 . Front plate 18 may be coupled to body 12 through the use of one or more fasteners 20 . Fasteners 20 may include threaded fasteners, pins, or any other appropriate fastener to couple front plate 18 to body 12 . In certain embodiments, front plate 18 may include one or more structures to lock or secure one or more fasteners 20 . For example, in embodiments utilizing a threaded fastener 20 as shown, front plate 18 may include one or more grooves and associated projections 26 to better secure fastener 20 in place.
[0034] In certain embodiments, front plate 18 may include an opening 19 that substantially aligns with opening 42 of adjustor 36 . In operation, opening 19 may provide access to opening 42 of adjustor 36 for locational adjustment of hook 28 . In certain embodiments, adjustor 36 may be threaded and may engage cooperative threads of adjustor passage 34 of hook 28 such that rotation of adjustor 36 moves hook 28 forward or rearward relative to body 12 .
[0035] Receiver 50 is configured to receive arm 46 of hook 28 such that forward adjustment of hook 28 pulls lower arch 104 forward. Receiver 50 may be fully integrated into, permanently coupled to, or separate and removable from lower arch 104 . In certain embodiments, receiver 50 may include one or more openings 52 that may be used to couple receiver 50 to lower arch 104 through the use of any appropriate fastener. In certain embodiments, receiver 50 may also include slot 48 separating front shelf 54 from rear shelf 56 . In operation, hook 28 may engage either front shelf 54 or rear shelf 56 . In certain embodiments, the use of rear shelf 56 may provide additional extension of lower arch 104 in the forward direction relative to the use of front shelf 54 .
[0036] Receiver 50 may be modified according to particular needs to provide increased flexibility. For example, the vertical location of front shelf 54 and/or rear shelf 56 relative to lower arch 104 may be adjusted or otherwise modified, either during or after initial construction of receiver 50 . As another example, receivers 50 with varying vertical dimensions may be provided, such that the use of a particular receiver 50 may be selected to define a prescribed vertical separation between upper arch 102 and lower arch 104 and thus a prescribed opening of the user's lower jaw. As another example, the vertical location of front shelf 54 and/or rear shelf 56 may be selected by coupling receiver 50 to lower arch 104 in either of two possible orientations (i.e., with a particular horizontal surface facing up or facing down). As another example, receivers 50 with varying horizontal dimensions may be provided, such that the use of a particular receiver 50 may be selected to define a prescribed forward location (or range of locations) for lower arch 104 relative to upper arch 102 .
[0037] Slot 48 may allow horizontal movement of lower arch 104 relative to upper arch 102 when lower arch 104 is coupled to upper arch 102 . Similarly, the posterior surface of front shelf 54 and/or rear shelf 56 may be shaped to guide the horizontal movement of lower arch 104 relative to upper arch 102 in an arc-shaped or other desirable path.
[0038] FIGS. 6A through 6C illustrate example hooks 28 with varying lengths, for use with adjustment mechanism 10 . In operation, the use of a particular hook 28 may be selected to define a prescribed vertical separation between upper arch 102 and lower arch 104 and thus a prescribed opening of the user's lower jaw. For example, in the embodiments shown, the use of hook 28 c may allow for greater vertical separation between upper arch 102 and lower arch 104 than the vertical separation allowed with the use of hooks 28 a or 28 b. In particular embodiments, the use of hooks 28 with varying lengths, together with the use of receivers 50 with varying vertical dimensions, may provide an increased range and/or precision for selection of a prescribed opening of the user's lower jaw.
[0039] FIGS. 7A through 7C illustrate example receivers with varying dimensions, for use with adjustment mechanism 10 . In operation, the use of a particular receiver may be selected to define a prescribed forward location (or range of forward locations) for lower arch 104 relative to upper arch 102 and thus a prescribed forward location (or range of forward locations) for the user's lower jaw. For example, in the embodiments shown, the use of receiver 50 c may allow for lower arch 104 to be positioned further forward with respect to upper arch 102 than with the use of receivers 50 a or 50 b. In particular embodiments, the use of receivers 50 with varying dimensions may provide an increased range and/or precision for adjusting the forward location of lower arch 104 relative to upper arch 102 .
[0040] FIGS. 8A through 10 illustrate an example adjustment mechanism 10 utilizing an example extender 60 . In certain embodiments, extender 60 couples to receiver 50 and operates to receive arm 46 of hook 28 such that the forward positioning of lower arch 104 is greater than that provided without extender 60 .
[0041] FIGS. 11A and 11B illustrate an example extender 60 for use with an example adjustment mechanism 10 . In certain embodiments, extender 60 may include a shelf 68 that engages arm 46 of hook 28 . In certain embodiments, extender 60 may also include one or more projections 66 that may cooperatively engage slot 48 of receiver 50 . In certain embodiments, extender 60 may also include one or more openings 64 that may cooperate with one or more fasteners 62 to couple extender 60 to receiver 50 , such as via slot 48 . Fastener 62 may be a threaded fastener, pin, or any other appropriate fastener for coupling extender 60 to receiver 50 .
[0042] FIGS. 12A and 12B illustrate example receivers 50 for use with example adjustment mechanisms 10 . As shown in FIG. 12A , in certain embodiments, receiver 50 may include only a single shelf 54 , in which case slot 48 may be fully or partially exposed in the rearward direction. As shown in FIG. 12B , receiver 50 may include notch 70 in slot 48 . In operation, the use of receiver 50 including only a single shelf 54 or including notch 70 may allow hook 28 to engage or disengage from shelf 54 of receiver 50 after oral appliance 100 has been inserted into a user's mouth.
[0043] FIG. 13 illustrates an example oral appliance 100 with an example adjustment key 80 . Adjustment key 80 may have a cross-section that is hexagonal, square, or any other appropriate shape. In certain embodiments, adjustment key 80 may be used to exert a rotational force on adjustor 36 causing adjustor 36 to turn and thereby provide adjustment of hook 28 , forward or rearward.
[0044] FIGS. 14 through 16 illustrate example adjustment mechanisms 10 utilizing example adjustment keys 80 . In certain embodiments, adjustment key 80 may be coupled to adjustment mechanism 10 through the use of retainer ring 82 and notch 84 . In operation, retainer ring 82 may engage notch 84 , thus preventing removal of adjustment key 80 . In operation, embodiments of adjustment mechanism 10 including adjustment key 80 and retaining ring 82 may be used by a particular user during a trial period for oral appliance 100 . During this trial period, the user and/or a clinician may make periodic adjustments to adjustment mechanism 10 through the use of adjustment key 80 to achieve the desired positioning of lower arch 104 relative to upper arch 102 . In these embodiments, once the desired positioning has been achieved, adjustment key 80 and retaining ring 82 may be removed. In these embodiments, once the desired positioning has been achieved, front plate 18 may be replaced with a front plate 18 that does not include an opening 19 .
[0045] FIGS. 17 through 19B illustrate an example oral appliance 100 with an example extension post 90 . Extension post 90 may be formed of any suitable material, such as a metal or hard plastic. In certain embodiments, extension post 90 may be used to couple oral appliance 100 to one or more other devices and/or to orient one or more other devices relative to oral appliance 100 . For example, extension post 90 may be used to couple oral appliance 100 to a venting seal or a gas delivery device, such as a face mask or a nose mask. In a particular embodiment, extension post may be used to couple oral appliance 100 to a mask associated with a continuous positive airway pressure (CPAP) system.
[0046] In certain embodiments, extension post 90 may be substantially rigid, to provide for sufficiently precise positioning of one or more devices relative to upper arch 102 . For example, in certain embodiments, extension post 90 may be used to provide substantially precise and repeatable positioning of a face mask or nose mask relative to upper arch 102 . The length of extension post 90 may vary depending upon its intended use. For example, extension post 90 may be substantially shorter if it is intended to be used to couple a venting seal to oral appliance 100 than if it is intended to couple a nose mask to oral appliance 100 . The invention contemplates any reasonable length of extension post 90 , so long as the length is appropriate to perform the intended function.
[0047] In certain embodiments, extension post 90 may include one or more features that can operate to index or assist in securing one or more devices to extension post 90 . For example, as shown in FIG. 19B , extension post 90 may include one or more locators 92 at one or more positions along the length of extension post 90 . In operation, a device coupled to or guided by extension post 90 may include one or more structures that can cooperate with the one or more locators 92 to index or assist in securing the device. In the embodiment shown, locator 92 is in the form of a notch, however, in alternative embodiments, locator 92 may be in the form of a ridge, protrusion, or any other appropriate shape or structure. In particular embodiments, the position of locator 92 may be adjustable.
[0048] In certain embodiments, extension post 90 may be coupled to front plate 18 .
[0049] In these embodiments, extension post 90 may be coupled through the use of any appropriate means, such as welding or threaded coupling. In alternative embodiments, extension post 90 may be integrally formed with front plate 18 . In certain embodiments, extension post 90 may be substantially hollow and may couple to front plate 18 such that the hollow interior of extension post 90 substantially aligns with an opening 19 . In operation, the hollow portion of extension post 90 may provide access to adjustor 36 through opening 19 . The cross-sectional shape of extension post 90 may take any appropriate form, so long as it remains reasonable for the intended function.
[0050] FIGS. 20A through 20C illustrate transverse cross-sectional views of example extension posts 90 . As shown, extension post 90 may have a cross sectional shape that is a circle, oval, or diamond. In certain embodiments, non-circular cross-sections may function to more precisely position a device coupled to oral-appliance 100 through the use of extension post 90 , by substantially limiting the likelihood that the device will rotate about the extension post 90 .
[0051] In certain embodiments, receiver 50 may be removable. For example, lower arch 104 may include a recess that allows receiver 50 to be positioned within, and then removed from, lower arch 104 . In embodiments including a removable receiver 50 and a recess in lower arch 104 , the recess may be integrally formed in lower arch 104 . In alternative embodiments, the recess may be formed in or by a housing that is included in lower arch 104 .
[0052] FIGS. 21 through 23 illustrate an example housing 94 , for use with an example adjustment mechanism 10 . In certain embodiments, adjustment mechanism 10 may include housing 94 to position and secure receiver 50 . Housing 94 may be made of any appropriate material, such as metal or hard plastic. In certain embodiments, housing 94 may be integrally formed with lower arch 104 . As shown, housing 94 may define recess 95 to accept receiver 50 within housing 94 . In certain embodiments, housing 94 may include one or more fasteners 96 to secure receiver 50 within recess 95 . In a particular embodiment, fastener 96 may be a threaded set-screw.
[0053] In certain embodiments, housing 94 may include one or more projections 98 that may be used to orient and/or secure housing 94 to lower arch 104 . In particular embodiments, as in the example shown in FIG. 23 , one or more projections 98 may be used to orient housing 94 to lower arch 104 . In these embodiments, once housing 94 is properly oriented, housing 94 may be luted to (or otherwise secured to) lower arch 104 . In certain embodiments, some or all of projections 98 may be removed before or after housing 94 is completely secured to lower arch 104 .
[0054] FIGS. 24A through 25C illustrate example receivers 50 , for use with an example housing 94 . As shown, receiver 50 may have varying dimensions and the location of certain features of receiver 50 may vary. In operation, the use of a particular receiver 50 may be selected to define a prescribed forward location (or range of locations) for lower arch 104 relative to upper arch 102 . For example, in the embodiments shown, the use of receiver 50 f may allow for lower arch 104 to be positioned further forward with respect to upper arch 102 than with the use of receivers 50 d and 50 e. In particular embodiments, the use of receivers 50 with varying dimensions may provide an increased range and/or precision for adjusting the forward location of lower arch 104 relative to upper arch 102 .
[0055] As shown in FIG. 24D , in certain embodiments, receiver 50 may include only a single shelf 54 , in which case slot 48 may be fully or partially exposed in the rearward direction. In operation, the use of receiver 50 including only a single shelf 54 (or including notch 70 ) may allow hook 28 to engage or disengage from shelf 54 of receiver 50 after oral appliance 100 has been inserted into a user's mouth.
[0056] As shown in FIGS. 25A through 25C , receiver may have varying vertical dimensions. In operation, the use of a particular receiver 50 may be selected to define a prescribed vertical separation between upper arch 102 and lower arch 104 and thus a prescribed opening of the user's lower jaw. For example, in the embodiments shown, the use of receiver 50 j may allow for greater vertical separation between upper arch 102 and lower arch 104 than the vertical separation allowed with the use of receivers 50 h and 50 i. In particular embodiments, the use of receivers 50 with varying vertical dimensions may provide an increased range and/or precision for selection of a prescribed opening of the user's lower jaw.
[0057] FIG. 26 illustrates an example coupler 120 , an example gas delivery device 110 , and example components of oral appliance 100 . In the embodiment shown, coupler 120 includes post 131 , clamps 128 , fasteners 126 , and swivel 122 .
[0058] In the depicted embodiment, post 131 includes base 136 and arms 132 configured such that post 131 is substantially U-shaped. Other suitable shapes may be used in various embodiments. For example, post 131 may be substantially V-shaped. FIGS. 27A-D illustrate an example embodiment of post 131 . As shown in FIG. 27B , arms 132 in the example embodiment extend at a substantially non-perpendicular angle to base 136 . The depicted embodiment in FIG. 27B illustrates that angle 137 (relative to plane 138 extending substantially along the mating surface of base 136 ) is formed between the junction of base 136 and arms 132 . The positioning of arms 132 may provide for a variety of suitable configurations for post 131 . In various embodiments, for example, arms 132 may extend at an angle 137 between 60 and 80 degrees. Although any suitable angle 137 may be used, in a particular embodiment, arms 132 may extend substantially perpendicularly from base 136 . In the depicted embodiments, arms 132 include channels 130 . Channels 130 may be smooth as depicted in FIGS. 26 and 27B . In various embodiments, other suitable shapes may be used. For example, channels 130 may include one or more structures (e.g., notches) to facilitate positioning of clamps 128 . Post 131 may be formed of any suitable material, including suitable plastics or metals as examples. In certain embodiments, post 131 may be formed of 304 stainless steel.
[0059] FIGS. 28A-29D show several perspectives of one embodiment of clamps 128 . In such embodiments, clamps 128 comprise protrusions 129 . Protrusions 129 may be used to engage channels 130 , as described further below. Protrusions 129 may be configured differently in various embodiments. For example, protrusions 129 may be configured to engage one or more structures in channels 130 to facilitate positioning of clamps 128 . Clamps 128 may also include threaded portions that facilitate advancement along channels 130 . Clamps 128 may be formed of any suitable material, including suitable plastics or metals as examples. In certain embodiments, clamps 128 may be formed of 304 stainless steel.
[0060] In some embodiments, fasteners 126 may be configured in a variety of manners such that fasteners 126 may be suitable for coupling to clamps 128 . Fasteners 126 may be threaded and the heads of fasteners 126 may be square, hexagonal, or any other appropriate shape to allow for a rotational force to be applied in order to secure fasteners 126 to clamps 128 . In some embodiments, fasteners 126 may not be threaded. The ends of fasteners 126 may have notches or other structures that allow fasteners 126 to lock into place with clamps 128 . Fasteners 126 may be formed of any suitable material, including suitable plastics or metals as examples. In certain embodiments, fasteners 126 may be formed of 304 stainless steel.
[0061] FIGS. 30A-D illustrate various embodiments of swivel 122 . In the depicted embodiments, swivel 122 is substantially spherical and includes opening 123 . In the example of FIG. 30A , opening 123 is substantially cylindrical while in the example of FIG. 30B , opening 123 includes a D-shaped passageway that may operate to index or orient gas delivery device 110 . Additionally, the D-shaped passageway may prevent rotation of swivel 122 relative to a post inserted into opening 123 . Other suitable configurations or shapes for opening 123 may be used. FIG. 30B illustrates an embodiment of swivel 122 wherein swivel 122 is substantially spherical with a flat top and bottom portion. Swivel 122 may, in various embodiments, take on other shapes, such as being substantially egg-shaped, and may or may not have a flat top and bottom. Swivel 122 may be formed of any suitable material, including suitable plastics or metals as examples. In particular embodiments, swivel 122 may be formed of acrylonitrile butadiene styrene (ABS) plastic or polycarbonate plastic.
[0062] In operation, in various embodiments, coupler 120 may be coupled to body 12 through post 131 . In particular embodiments, base 136 may be fastened to body 12 through fastener passages 22 of body 12 and fastener passages 133 of base 136 using fasteners 20 . Although two threaded fasteners 20 are illustrated, any suitable technique may be used to couple post 131 to oral appliance 100 . For example, post 131 may be integrally formed with one or more components of oral appliance 100 . As another example, pins may be used to couple post 131 to oral appliance 100 .
[0063] Clamps 128 may be used, in some embodiments, to secure swivel 122 to post 131 . Clamps 128 may be configured to slideably engage each arm 132 using channels 130 and protrusions 129 . Clamps 128 may be secured to arms 132 using fasteners 126 that, for example, pass through clamp 128 a, extend across the gap between arms 132 a and 132 b, and terminate at clamp 128 b. In such a manner, the position of swivel 122 relative to base 136 may be determined by the location of clamps 128 along channels 130 . Swivel 122 may be positioned between arms 132 and further secured by fasteners 126 .
[0064] Swivel 122 , in various embodiments, may be secured by clamps 128 and fasteners 126 (as depicted in FIGS. 31A-B ) in a manner that allows swivel 122 to rotate along at least one axis. Swivel 122 may be configured to engage gas delivery device 110 . For example, gas delivery device 110 may include coupling platform 112 . In some embodiments, platform 112 and opening 123 may use the same shapes so as to facilitate coupling platform 112 to swivel 122 . In particular embodiments, coupling platform 112 may be shaped substantially cylindrically such that it may engage a substantially cylindrical opening 123 of swivel 122 . In alternative embodiments, swivel 122 may be integrally formed with gas delivery device 110 or with other components such that no opening is required. In the embodiment shown, swivel 122 includes a notch to allow swivel 122 to be compressed to adjust the diameter of opening 123 . Rotating swivel 122 while it is secured to post 131 and platform 112 may allow gas delivery device to be positioned in a suitable manner to properly fit to a patient's face. The freedom of movement allowed by coupler 120 allows gas delivery device 110 to be comfortably and effectively fitted to the patient's unique facial features and preferences. Once they are so fitted, fasteners 126 are tightened so as to maintain this comfortable and effective orientation between gas delivery device 110 and oral appliance 100 . In some embodiments, gas delivery device 110 may be further positioned while being secured to platform 112 by moving swivel 122 closer to or away from base 136 of post 131 . This, in some embodiments, may be accomplished by sliding clamps 128 along channels 130 . During use, oral appliance 100 will be securely in place in the patient's mouth. Because it is connected to gas delivery device 110 through coupler 120 , oral appliance 100 acts as an anchor, maintaining the orientation and fit of gas delivery device 110 .
[0065] Although the described embodiment is with an oral appliance that extends the lower jaw forward to more fully open the breathing passageway of the patient, coupler 120 may also be used with oral appliances that do not perform this function. As discussed above, example oral appliance 100 is used with coupler 120 to anchor gas delivery device 110 . In alternative embodiments, other oral appliances may be used to anchor a gas delivery device. For example, an upper arch alone could be used with coupler 120 to connect to gas delivery device 110 . Furthermore, oral appliances not shaped as arches could also be used with coupler 120 . Indeed, in the context of an oral appliance coupled to a gas delivery device, the term oral appliance is meant to include any device which can fit within the oral cavity and serve as an anchor for the gas delivery device.
[0066] The components of coupler 120 may be formed of any suitable material, including suitable plastics or metals as examples. In certain embodiments, post 131 and clamps 128 may be formed of 304 stainless steel. Fasteners 126 may include threaded fasteners, pins, or any other appropriate fastener to couple clamps 128 to arms 132 .
[0067] FIG. 27C illustrates passageway 134 which may allow items such as key 80 and post 90 to pass through so that oral appliance 10 may be adjusted while coupled to coupler 120 . For example, adjustment key 80 may be inserted through passageway 134 while swivel 122 is engaged or disengaged from post 131 in order to adjust oral appliance 10 (as described above) even though post 131 is secured to body 12 .
[0068] FIG. 31 illustrate embodiments of coupler 120 including sleeve 140 . Sleeve 140 , in the depicted embodiments, covers a portion of coupler 120 . In various embodiments, sleeve 140 may be made out of rubber, silicon, or other suitable materials. Sleeve 140 may be used to enhance the comfort and/or safety of a user of oral appliance 100 and gas delivery device 110 . For example, sleeve 140 may help protect portions of a user's mouth or face from being irritated by the use of coupler 120 .
[0069] FIG. 32 illustrates an example method of improving a user's breathing, indicated generally at 200 . At step 202 , upper arch 102 is inserted into the user's mouth. At step 204 , lower arch 104 is inserted into the user's mouth. At step 206 , upper arch 102 is coupled to lower arch 104 by adjustment mechanism 10 . In certain embodiments, adjustment mechanism 10 includes a body 12 coupled to upper arch 102 , an adjustor 36 , a hook 28 , and a receiver 50 coupled to lower arch 104 . In certain embodiments, upper arch 102 is coupled to lower arch 104 by engaging shelf 54 of receiver 50 with arm 46 of hook 28 . In particular embodiments, the initial forward position of lower arch 104 relative to upper arch 102 is determined by engaging a particular one of multiple shelves 54 of receiver 50 . In alternative embodiments, the initial forward position of lower arch 104 relative to upper arch 102 is determined by engaging shelf 68 of extender 60 coupled to receiver 50 . At step 208 , the forward position of lower arch 104 relative to upper arch 102 is adjusted to facilitate improved breathing by the user. In certain embodiments, the forward position is adjusted by rotating adjustor 36 using adjustment key 80 or in any other appropriate manner.
[0070] FIG. 33 illustrates an example method of coupling a gas delivery device to an oral appliance, indicated generally at 210 . At step 212 , gas delivery device 110 is coupled to oral appliance 100 . In certain embodiments, gas delivery device 110 may be coupled to oral appliance 100 using coupler 120 with arms 132 , clamps 128 , and swivel 122 . In particular embodiments, swivel 122 may couple to gas delivery device 110 at mounting platform 112 .
[0071] At step 214 , gas delivery device 110 is positioned. This may be done by adjusting clamps 128 along channels 130 . In addition, in some embodiments, swivel 122 may be adjusted in order to further refine the position of gas delivery device 110 . In certain embodiments, this may include rotating swivel 122 about at least one axis while swivel 122 is positioned between clamps 128 .
[0072] At step 216 , gas delivery device 110 is secured. This may be accomplished by tightening fasteners 126 so that clamps 128 are secured to arms 132 . Tightening fasteners 126 may also secure the position of swivel 122 , thus securing the orientation of gas delivery device 110 . In some embodiments, this may cause gas delivery device 110 to be positioned appropriately for the user by orienting swivel 122 to post 131 . In certain embodiments, post 131 may be coupled to oral appliance 100 at body 12 .
[0073] Although example methods are described, the steps may be accomplished in any appropriate order. For example, in method 200 , inserting the upper and lower arches can be accomplished sequentially, in any order, or simultaneously. As another example, upper arch 102 and lower arch 104 may be coupled subsequent to or prior to inserting upper arch 102 and lower arch 104 into the user's mouth. As another example, the adjustment of the forward position of lower arch 104 relative to upper arch 102 may be performed in measured increments interspersed with trial periods to test the effectiveness of the oral appliance in improving the user's breathing. Method 200 may include checking or verifying the forward position of lower arch 104 relative to upper arch 102 and then repeating step 208 as needed. In certain embodiments, method 200 may include checking or verifying the position of gas delivery device 110 relate to the user and then repeating steps 208 and 210 as needed. The present invention contemplates using methods with additional steps, fewer steps, or different steps, so long as the methods remain appropriate for improving a user's breathing.
[0074] Although the present invention has been described in connection with several embodiments, it should be understood that a variety of changes, substitutions, variations, alterations, transformations, and modifications may be suggested to one of skill in the art, and it is intended that the present invention encompass such changes, substitutions, variations, alterations, transformations, and modifications as fall within the spirit and scope of the appended claims. | According to one embodiment, an apparatus for coupling an oral appliance to a gas delivery device includes a post, a swivel, and first and second opposing clamps. The post includes a base configured to couple to the oral appliance; a first arm extending from the base and defining a channel extending along a portion of the first arm; and a second arm extending from the base, extending substantially parallel to the first arm, the second arm defining a channel extending along a portion of the second arm. The swivel is substantially spherical and is configured to position the gas delivery device. The first clamp is configured to engage and slide along the channel defined by the first arm and the second clamp is configured to engage and slide along the channel defined by the second arm. The first and second opposing clamps are together configured to position and secure the location and orientation of the swivel relative to the post. | 0 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
The present application claims priority from Provisional Patent application No. 60/092,957, filed on Jul. 13, 1998, herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates generally to spread spectrum communication systems that utilize an inter-frequency search. More particularly, a technique for performing an inter-frequency search with reduced or eliminated loss of link frames is described.
Wireless communication systems have grown dramatically in popularity in recent years. In typical wireless communication systems, mobile stations (e.g., a cellular telephone) communicate with other mobile stations via base stations. To date, a variety of cellular networks have been implemented, and one of the increasingly popular types of networks is referred to as a code division multiple access (CDMA) system.
FIG. 1 provides an overview of a CDMA system. In this system, mobile switching center 10 provides simultaneous communications among multiple base stations 20 while simultaneously routing calls from one or more base station 20 to public switched telephone network (PSTN) 30 . PSTN 30 communicates with, for example, telephone 40 . The mobile switching center's simultaneous routing makes handoffs between base station 20 and other base stations more reliable. CDMA base stations use one or more CDMA radio channels to provide both control and voice functionality. Base station 20 converts the radio channel to a signal that is transferred to and from mobile switching center 10 . Base station 20 can also communicate simultaneously among different sections in a cell, enhancing handoffs. Base station 20 communicates with, for example, mobile stations 50 , 52 and 54 . Mobile stations 50 , 52 and 54 can be, for example, mobile telephones and other types devices that provide wireless communication, such as PCSs, laptop computers or PDAs.
In a CDMA system, there are two types of handoffs, soft and hard. In a soft handoff, the mobile station is allowed to communicate with two or more cell sites enhancing the signal quality. These cell sites must share the same frequency. The CDMA mobile station measures the pilot channel signal strength from adjacent cells and transmits the measurements to the serving base station. The pilot channel provides a reference for coherent channel demodulation and is used as a reference signal level for handoff decisions. The mobile station must be synchronized to the pilot channel pseudo noise (PN) phase before accessing any other control channel. When an adjacent base station's pilot channel signal is strong enough, the mobile station moves the base station pilot into a candidate set and sends a pilot strength measurement message indicating the pilot signal energy. Now, both base stations (i.e., the current and the new one) send an extended handoff direction message, which requests the addition of the new base station pilot to the mobile stations active set of pilots. The new base station also starts transmitting a signal to the mobile station, while the mobile station tunes to the arriving signal from the new base station. This tuning occurs when the mobile station assigns a demodulating element (e.g., a finger on a rake receiver) to the arriving signal. Thus, during the soft handoff, the mobile station is communicating with both base stations simultaneously. During soft handoff, the mobile station utilizes time diversity to use signals from both base stations. The mobile station adds the new signal in a maximum ratio combiner before the decoding.
In contrast, during a hard handoff, the mobile station terminates the communication link with the current servicing base station before establishing the link with the new base station. This technique is similar to the technique used in time division multiple access (TDMA) and global system for mobile communication (GSM) systems. Hard handoffs occur when the mobile station's receiver is switching between a base station of one frequency and a base station of a different frequency. Usually, there is only one receiver in a mobile station, and that receiver can only receive data from one frequency at any given time. Therefore, a soft handoff is not possible when switching between base stations with different frequencies. FIG. 2 illustrates base stations with different frequencies. For example, cells 100 , 104 , 108 , 114 , 116 and 118 use a first frequency and cells 102 , 106 , 110 , 112 and 120 use a second frequency. Microcells 106 and 110 are used, for example, in shopping malls, office buildings and other indoor facilities.
Currently available hard handoff techniques can result in a dropped or lost telephone call. If the searcher in the cellular telephone mobile station uses, for example, a sequential sliding correlator (SSC) algorithm, and the search window size is 192 clips, then the total search time for a typical system with a 1× spreading note is as follows:
SF = 192 × C L × 0.8 - 6 [ S ] = 192 × 768 × 0.8 - 6 = 0.18 seconds
where: C L is the average correlation length to achieve 0.99 depiction probability or approximately 20 frames. Because the frequency search message contains more than one base station offset in this example, the loss of service quality can be significant if the mobile station performs all searches in one period. If 20 frames are lost, then the telephone call will likely be so dropped.
The IS-95 standard combines new digital CDMA and advanced mobile phone service (AMPS) functionality. IS-95A CDMA systems do not allow for inter-frequency searches because of the continuous nature of the CDMA waveforms. The inter-frequency search, also called mobile assisted hard handoff, was introduced in the IS-95B CDMA standard. The mobile assisted hard handoff can be performed without any timing restrictions (i.e., there is no restriction on the length of time used for this handoff). As a result, the mobile station is allowed to erase as many data frames (or portions of data frames) of the forward or reverse links as needed to perform the inter-frequency search.
The forward link is the data link from the base station to the mobile station, and the reverse link is the data link from the mobile station to the base station.
Currently, the CDMA mobile station performing the inter-frequency search will erase one or more of forward link frames and reverse link frames.
The IS-95B standard includes a gated-off transmission technique on the reverse link. A gated-off transmission is used when voice activity is low, and this allows voice data to be sent at different rates depending on the voice activity. For example, when voice activity drops to a low rate (e.g., ⅛ of the full rate), the transmission can be gated-off such that ⅛ of the normal amount of date is transmitted. This gated-off transmission on the reverse link allows the mobile station to perform the inter-frequency search during the period when the transmitter is gated-off. This technique minimizes the impact on the reverse link.
A mobile station in a third generation CDMA system, such as cdma2000, does not gate-off its transmitter during the transmission of lower rates. Thus, the erasure (i.e., loss) of both forward and reverse link frames is particularly true in this situation. Most of the third generation CDMA systems allow for a mixture of different classes of service, such as speech over data. In the cdma2000 system, this is achieved by allowing a simultaneous transmission on many physical channels. For example, fundamental channels and supplemental channels each carry a different payload. Additionally, since speech is carried on a fundamental channel and uses variable (i.e., speech activity driven) data rates, while a supplemental channel usually uses higher fixed (i.e., assigned) data rates, it is eminent that one or both of these channels will experience erasure during the inter-frequency search. Therefore, the likelihood of erasing links increases with, for example, the cdma2000 standard because the cdma2000 standard allows the mixing of different classes of services (e.g., data and voice services) on the fundamental and supplemental channels. It is desirable to have an inter-frequency search with minimal loss link frames in a CDMA system.
SUMMARY OF THE INVENTION
The present invention provides a technique for performing an inter-frequency search with reduced or eliminated loss of link frames in a CDMA system. In the preferred embodiment, the CDMA system includes a base station and a mobile station. The mobile station has a searcher, which measures the signal strength of the base station pilot channels. The signal strengths of these pilot channels are then reported to the base station. Usually, there is only one RF receiver in the mobile station. Thus, the mobile station cannot receive data on one frequency while searching for pilot channels on another frequency. As a result, this searching during a hard handoff produces erased portions of at least one data frame.
Before the search on the candidate frequency is performed, the mobile station informs the base station of the parameters related to the search. In the preferred embodiment, these parameters include the frame of the search, the start position of the search, and the length of the search. This allows the mobile station and/or the base station to replace the erased portions of the frame(s) with corrective data such as soft zeros.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 provides an overview of a CDMA system;
FIG. 2 illustrates cells of base stations with different frequencies;
FIG. 3 illustrates a device configuration for implementing the present invention;
FIG. 4 provides a process flowchart for the inter-frequency search of the present invention;
FIG. 5 provides a diagram illustrating one procedure used by the present invention;
FIG. 6 provides a process flowchart for one embodiment of the present invention;
FIG. 7 provides a process flowchart for an autonomous inter-frequency search; and
FIG. 8 provides a process flowchart for an inter-frequency search with full rate determination.
DETAILED DESCRIPTION
The present invention provides several embodiments for providing an inter-frequency search procedure that significantly reduces additional power requirements while achieving comparable or better performance. FIG. 3 illustrates a device configuration for implementing the present invention. A band limited signal is filtered by low pass filter 130 and then received by analog to digital converter 132 (A/D converter). A pseudo random sequence from base station 1 is received by multiplier 140 along with the signal exiting A/D converter 132 . The signal from multiplier 140 is sent to channel estimator 142 and multiplier 144 . Multiplier 144 also receives a Walsh code from base station 1 . The signals from channel estimator 142 and multiplier 144 are then sent to phase corrector 146 . In this example, phase corrector 146 is also a multiplier. A similar operation is performed for base station 2 with multiplier 150 , channel estimator 152 , multiplier 154 and phase corrector 156 . In this example, phase corrector 156 is not a multiplier. The sum of the signals from phase correctors 146 and 156 are then sent as soft data to viterbi decoder 158 in the preferred embodiment. In FIG. 3 , the thin signal lines represent real data, and the thick signal lines represent complex data.
The signal from AND converter 132 is also sent to multiplier 160 . Multiplier 160 also receives a pseudo random sequence from another base station. The signal from multiplier 160 is sent to searcher 164 and then to controller 166 . Searcher 164 and controller 166 perform the inter-frequency search.
FIG. 4 provides a process flowchart for the inter-frequency search of the present invention. At step 200 , the mobile station receives a candidate frequency search control message (CFSCM). At step 201 , the mobile station informs the base station of the position and the length of the search on frequency f2. At step 202 , the mobile station tunes its receiver from frequency f1 to frequency f2. At step 204 , the mobile station performs the search of f2 Pilots. In this embodiment, the mobile station's receiver can only receive data on one frequency at one given time. Therefore, during the search time, no data is received from frequency f1. At step 206 , the mobile station returns to frequency f1 and continues normal operation. At step 208 , the mobile station reports the frequency f2 Pilots' strength to the base station. During the time the mobile station is searching the frequency f2 (i.e., search time), the frequency f1 forward and reverse links are disrupted. This results in a negative impact on the quality of service of data transferred on frequency f1. The present invention allows the mobile station to perform the inter-frequency search while minimizing frame erasure on the forward and reverse links. This reduces or eliminates the negative impact on the quality of service.
At step 212 in FIG. 4 , the mobile station replaces the erased portion of the frame with, for example, soft zeros. Thus these soft zeros are used to replace any data received in error from frequency f2 and to minimize the negative impact on the quality of service. Alternatives to soft zeros can also be utilized in the present invention.
If the inter-frequency search period is short relative to the length of the frame, then the probability of losing the forward channel frame is low because the transmitted symbols are interleaved over the entire frame period. When the inter-frequency search period is short, the inter-frequency search disruption of the forward channel can be seen as a fade (i.e., loss of signal for a short period of time or lowering of the power) of the received signal. If the inter-frequency search position and length are known to the base station, it can also perform the same operation (i.e., replacing the erased portion of the frame with soft zeros), thus minimizing the impact on the reverse link. This is shown in step 214 of FIG. 4 .
In the preferred embodiment, a dedicated message is used to provide the inter-frequency search communication and synchronization between the base station and the mobile station. This message is referred to as a candidate frequency search position message (CFSPM) and may be placed, for example, on the reverse dedicated control channel (R-DCCH) or on the reverse common control channel (R-CCCH) to indicate the position and the length of the inter-frequency search. The R-DCCH is dedicated to one mobile station, and the R-CCCH is for all mobile stations.
In another embodiment of the present invention, the synchronization is provided by the base station. In this embodiment, the base station pushes search parameters to the mobile station, such that the inter-frequency search is performed at the action time specified in a message from the base station. In either embodiment, the search position can be defined in, for example, units of power control group (PCG) or in milliseconds. In the IS-95B and cdma2000 standards, the length of the PCG is 1.25 ms (800 Hz).
FIG. 5 provides a diagram illustrating one procedure used by the present invention. In this diagram, 220 identifies the forward channel and 222 identifies the reverse channel. Frame N+n contains data received by the rake receiver, which is located in the mobile station. Data sections 230 and 232 were received while the receiver was tuned to frequency f1. The receiver was tuned from frequency f1 to frequency f2 at start time position 236 . Date section 238 was received while the receiver was tuned to frequency f2. Thus, time 236 provides the start time or position of the inter-frequency search, and section 238 provides the duration or length of the inter-frequency search.
In the preferred embodiment, the following three parameters are used to characterize the inter-frequency search (IFS): (1) the frame in which the search is performed, (2) the start of the search within the frame, and (3) the length of the search. In the preferred embodiment, the message contains the following fields:
IFS_FRAME_OFFSET 6 bits (describes the frame position from CFSPM message) IFS_START_PCG 4 bits (defines the PCG in which IFS starts) IFS_LENGTH_PCG 4 bits (defines the # of PCG used for IFS search)
FIG. 6 provides a process flowchart for one embodiment of the present invention. At step 240 , the mobile station (MS) is demodulating frequency f 1 (see also section 230 in FIG. 5 ). At step 242 , the mobile station is directed by the base station (BS) to perform a search of frequency f 2 . At step 244 , the mobile station sends the candidate frequency search position message (CFSPM) on frequency f 1 with the above-described parameters (e.g., searched frame, search start position and search length). At step 246 , in the frame specified by the parameter IFS_FRAME_OFFSET, the base station waits until PCG is specified in parameter IFS_START_PCG. Then, at step 248 , to overcome the loss of the reverse link symbols, the base station replaces the indicated portion of the frame with soft zeros. For example, zeros are inserted by the following:
For IFS 13 LENGTH_PCG
Rx_SYMBOLS<=‘soft_zeros’
At step 250 , the mobile station performs the same operation for the forward traffic channel frame.
In another embodiment, the mobile station performs the inter-frequency search autonomously without network knowledge. FIG. 7 provides a process flowchart for an autonomous inter-frequency search. At step 260 , the mobile station monitors speech activity when it is present on the reverse channel. At step 262 , the mobile station checks for a natural drop in speech activity. When the speech rate drops to a low rate (e.g., ⅛ of the normal rate), the process moves to step 264 , and the mobile station performs the inter-frequency search for a fraction of the frame period (e.g., for several power control groups).
During the inter-frequency search, the mobile station receiver is tuned to frequency f2. Therefore, the mobile station does not receive any signal on the serving frequency f 1 . This will normally cause an erasure of a portion of the forward link frame. However, since the mobile station knows the timing of the inter-frequency search, it can replace the missing channel symbols with the soft zeros. If the inter-frequency search period is relatively short in comparison to the length of the frame, then the probability of losing the forward channel frame is low because the transmitted symbols are interleaved over the entire frame period. In this embodiment, the inter-frequency search disruption of the forward channel can be seen, for example, as a flat (i.e., shadow) fade of the received signal.
In yet another embodiment of the present invention, data rates on multiple channels are determined. FIG. 8 provides a process flowchart for an inter-frequency search with full rate determination. At step 270 , the mobile station again monitors speech activities. When the speech rate drops below a predetermined threshold at step 272 , the process moves to step 274 . At step 274 , the mobile station drops the data rate for the reverse supplemental channel such that its data rate matches the data rate of the reverse fundamental channel. As set forth above, the supplemental channel usually carries data with a higher, fixed rate, and the fundamental channel usually uses a variable data rate that is speech activity driven. If the data rates on both channels are the same, then the position and length of the inter-frequency search will be the same on both channels. This simplifies the correction procedure when both channels are in use (e.g., in voice over IP applications).
In normal operation, the base station only checks the reverse fundamental channel for data rate variation because the data rate on the supplemental channel is normally fixed. Therefore, an alteration must be made so that the base station is aware of the rate change on the supplemental channel. In one embodiment, the base station is notified of the change in data rate on the supplemental channel. In this embodiment, the candidate frequency search response message can be used to notify the base station of the change in data rate at step 276 . This notification can be placed, for example, in a new field that is added into the candidate frequency search response message or in the reserved bits of this message. At step 278 , the base station performs a rate determination on the reverse fundamental channel. At step 280 , the base station uses the rate from this rate determination for both the reverse fundamental channel and the reverse supplemental channel.
In a another embodiment, the base station performs a rate determination on the reverse supplemental channel without any notification from the mobile station. At step 290 , the process moves forward only if the base station directs the mobile station to perform an inter-frequency search. At step 292 , the process moves forward only if the base station receives a low data rate frame on the reverse fundamental channel (e.g., ⅛ of the full data rate). At step 294 , the base station performs rate determinations on both the fundamental channel and the supplemental channel. Therefore, the base station detects the rate change on the supplemental channel.
The present invention can be used with any CDMA system that includes a continuous channel or any other wideband CDMA system such as UMTS. | The present invention a system and method are provided for performing an inter-frequency search with reduced loss of link frames in a CDMA system. The CDMA system includes a base station ( 20 ) and a mobile station ( 50 ). The mobile station ( 50 ) has a searcher ( 164 ), which searches for pilot channels. The signal strengths of these pilot channels are then reported to the base station ( 20 ). This searching results in erased portions of a data frame ( 238 ). After the signal strengths are reported to the base station ( 20 ), the mobile station ( 50 ) informs the base station ( 20 ) of the parameters related to the search. These parameters may include the frame of the search, the start position of the search, and the length of the search. The mobile station ( 50 ) and the base station ( 20 ) then replaces the erased portions of the frame with corrective data such as soft zeros. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application, the contents of which are related to United States U.S. non-provisional patent application Ser. No. 11/483,076 filed on Jul. 7, 2006, which claims priority from non-provisional patent application having Ser. No. 10/410,486 filed on Apr. 3, 2003, now U.S. Pat. No. 7,084,766, which in turn claims priority to a provisional application having Ser. No. 60/371,063 filed on Apr. 8, 2002, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to security tags in general, and in particular to a tag body containing at least one frangible vial containing a detrimental substance and an attaching means for use in electronic article surveillance (EAS) tags.
BACKGROUND OF THE INVENTION
Various types of electronic article surveillance (EAS) systems are known having the common feature of employing a marker or tag which is affixed to an article to be protected against theft, such as merchandise in a store. When a legitimate purchase of the article is made, the marker can either be removed from the article, or converted from an activated state to a deactivated state. Such systems employ a detection arrangement, commonly placed at all exits of a store, and if an activated marker passes through the detection system, it is detected by the detection system and an alarm is triggered. In addition, other tags are known that utilize ink vials that break and release a permanent staining fluid onto the article if the tag is not removed by an authorized individual.
For example, U.S. Pat. No. 5,426,419 to Nguyen et al., and assigned to Sensormatic Electronics Corporation, discloses an EAS tag having an arcuate channel that extends from an opening thereof to the actual attaching assembly and the detaching mechanism thereof. The channel increases the susceptibility of defeat of the attaching assembly because it guides an object that is inserted by an unauthorized individual directly to the attaching assembly and allows disengagement thereof. In addition, that the tag may be cut in half at the store such that the electronic components are left at the retail location and the unscrupulous individual absconds with the garment because the electronic detectors cannot detect the tag. In a safe environment away from the retail location and without any urgency, the unscrupulous individual is able to defeat the attaching pin.
U.S. Pat. No. 6,373,390 to Hogan et al., assigned to the same assignee as the '419 patent, is an improvement patent issued in light of the shortcomings of the '419 patent. The '390 patent admits that the EAS tag of the '419 patent “can be defeated by insertion of a segment of relatively rigid metal bent in an arcuate manner to simulate the arcuate probe of the associated detacher device.” Furthermore, the '390 patent describes a fish tape which may be formed to resemble the requisite arcuate probe in order to defeat the EAS tag of the '419 patent, “the formed fish tape 50 is strong enough to hold its form when pushed into arcuate channel 7 until it can be manipulated into and against member 6, which then can be rotated to release tack assembly 4.” However, the improvement does not address the cutting of the tags by unscrupulous individuals to defeat detection of the electronic components.
With respect to the '419 and '390 patent, many free standing arcuate probes have been either manufactured or misappropriated by unscrupulous individuals by dismantling the detacher components with which the probes are associated. The arcuate probe is inserted into the arcuate channel by hand and is led directly to the preventing mechanism. In the '390 device, the arcuate channel leads the manipulated arcuate probe to the opening or slot located in the arcuate channel, wherein the opening further aligns and guides the hand manipulated probe directly to the preventing mechanism or member. In addition, the force required to release the preventing mechanism of the '419 and '390 device is less than the force required to release the preventing mechanism of the instant invention. Accordingly, an unscrupulous individual may easily defeat the preventing mechanism of the '419 and '390 devices by manipulating an illicitly acquired freestanding arcuate probe.
The '419 and '390 devices may be defeated by penetrating the bottom housing in proximal relation to the preventing mechanism and inserting a rigid and elongated element and forcing metal clip to rotate, whereby the preventing mechanism will release the pin. The instant device is more difficult to defeat in this manner because it will result in breakage of the ink vial to release the permanent staining substance onto the article.
In addition, the preventing mechanism of the '419 and '390 patents is attached on only one end thereof, thus allowing movement out of the horizontal plane. Consequently, the vertical movement of the clamp increases the susceptibility of defeat of the attaching assembly because the jaws expand more easily because the angle of the clamp varies between the first end and second end as a result of the vertical movement of the non-secure end. The pull force to disengage a pin from the instant device and the '419 device was conducted by using an Imada product model DPS220R, obtainable from 450 Skikie Blvd. #503, N. Brook, Ill. 60062.
The prior art does not address the need for an EAS tag that is difficult to defeat. In addition, the prior art fails to provide a clamp assembly that requires greater pull force to disengage a pin from the clamp assembly. In addition, the prior art fails to provide a tag that is more difficult to defeat even when an unscrupulous individual has illicitly acquired a freestanding arcuate probe. Further, the prior art fails to address the severance of the electronic component from the attaching component as a way to unscrupulously remove the article from the retail environment. Therefore, there remains a long standing and continuing need for an advance in the art of EAS tags that is more difficult to defeat, is simpler in both design and use, is more economical, efficient in its construction and use, and provides a more secure engagement of the article.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.
Therefore, it is a primary objective of the invention to provide an EAS tag that is more difficult to defeat.
It is another objective of the invention to provide a cost-efficient EAS tag.
It is another objective of the invention to provide an EAS tag that releases a detrimental substance if it is tampered with.
It is yet another objective of the invention to provide an EAS tag that decreases the likelihood of defeat by an unscrupulous individual.
It is a further objective of the invention to provide an EAS tag that is detachable when used with an authorized detaching unit.
In keeping with the principles of the present invention, a unique EAS tag is disclosed wherein an ink vial is housed within the tag body to prevent cutting off of the electronic region of the tag body from the attachment region of the tag that attaches the tag to the object to be monitored. In addition, the ink vial deters unscrupulous individuals from tampering with tags that are capable of functioning with probes that disengage the attaching mechanisms.
Such stated objects and advantages of the invention are only examples and should not be construed as limiting the present invention. These and other objects, features, aspects, and advantages of the invention herein will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
It is to be understood that the drawings are to be used for the purposes of illustration only and not as a definition of the limits of the invention. In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 is a side elevational view of the tag of the instant invention in an assembled state.
FIG. 2 is a side elevational view of the tag of the instant invention in an unassembled state.
FIG. 3 is a perspective exploded view of the tag of the instant invention and the components thereof.
FIG. 4 is a top plan view of the interior of second half of the instant tag with the tracks installed.
FIG. 5 is a top plan view of the interior of second half of the instant tag with the tracks and the attaching member installed.
FIG. 5A is an exploded view of an alternate preferred embodiment of the tag body incorporating the vial.
FIG. 5B is an exploded view of another alternate preferred embodiment of the tag body incorporating the vial.
FIG. 5C is an exploded view of another alternate preferred embodiment of the tag body incorporating the vial.
FIG. 6 is a top plan view of the interior of first half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member.
FIG. 7 is a top plan view of the interior of second half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member that attaches to first half illustrated in FIG. 6 .
FIG. 8 is a top plan view of the interior of first half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member.
FIG. 9 is a top plan view of the interior of second half of the instant tag with the attaching member installed illustrating an alternate preferred embodiment for accommodating an alternate resilient member that attaches to first half illustrated in FIG. 8 .
FIG. 10 is a perspective view of the interior of first half of the instant invention.
FIG. 11 is a perspective view of the interior of second half of the instant invention without the components therein.
FIG. 11A is a perspective view of the interior of second half of the instant invention with the tracks and attaching member installed.
FIG. 12 is a perspective view of a pin used with the instant invention.
FIG. 12A is a frontal perspective view of the attaching member of the instant invention.
FIG. 12B is a front elevational view of the attaching member of the instant invention.
FIG. 12C is a side perspective view of the attaching member of the instant invention.
FIG. 12D is a top perspective view of the first and second tracks used in the instant invention.
FIG. 13 is a top plan view of the interior of the first half of an alternate preferred embodiment of the instant invention illustrating additional pillars and walls that may be placed within the tag to thwart an unauthorized probe insertion.
FIG. 13A is a top plan view of the interior of the second half of an alternate preferred embodiment of the instant invention illustrating additional pillars and walls that may be placed within the tag to thwart an unauthorized probe insertion that attaches to first half illustrated in FIG. 13 .
FIG. 14 is a top plan view of the interior of the first half of an alternate preferred embodiment of the instant invention illustrating additional pillars that may be placed within the tag to thwart an unauthorized probe insertion.
FIG. 14A is a top plan view of the interior of the second half of an alternate preferred embodiment of the instant invention illustrating additional pillars that may be placed within the tag to thwart an unauthorized probe insertion and attaches to the first half illustrated in FIG. 14 .
FIG. 15 is an electrical schematic diagram of the resonant tag circuit.
FIG. 16 is a perspective view of the resonant tag circuit.
FIG. 17 is a block diagram of an article surveillance system incorporating the resonant tag circuit.
FIG. 18 is a cross-sectional view of a resonant tag system taken along line 18 - 18 of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 , a tag 20 is illustrated having a first half 22 and a second half 24 . First and second halves 22 and 24 are preferably made of a hard or rigid material. A usable rigid or hard material might be a hard plastic such as, for purposes of illustration but not limitation, an injection molded ABS plastic. If a plastic material is used, the mating of a first side wall 26 to a second side wall 28 can accomplished via an ultrasonic weld or like joining mechanism. However, it is to be understood that other joining methods, such as adhesives, may also be used. When first half 22 and second half 24 are securely joined, first sidewall 26 and second sidewall 28 form a peripheral outer wall of tag 20 . Second half 24 has an apex region 25 that extends therefrom in an opposing direction to first half 22 .
Now referring to FIGS. 3 , 4 , 5 , 11 , and 11 A, an exploded perspective view, top plan view, and perspective views illustrate the interior of second half 24 . Second half 24 receives at least a first track 30 therein, and in a preferred embodiment it also receives a second track 32 . First track 30 is tightly received within at least a first slot 31 and second track 32 is received tightly within at least a second slot 33 , such that tracks 30 and 32 are maintained in substantially parallel relations. Tracks 30 and 32 are made of a hard material such as, but not limited to, metal, which enhances the durability and performance of the tag 20 .
An attaching member 34 , as described in greater detail hereinafter, slideably rests on at least first track 30 , but in a preferred embodiment, rests on both first and second tracks 30 and 32 . Attaching member 34 has a resilient member 36 that normally maintains an opening 38 defined on said attaching member 34 in axial alignment with an aperture 40 defined on the inside of second half 24 and a hole 42 defined on the interior of first half 22 . In one preferred embodiment, attaching member 34 is made of spring sheet metal. Resilient member 36 may be a resilient lever arm 43 and in an alternate preferred embodiment, as illustrated in FIGS. 7 and 9 , at least one spring 44 may be substituted for the resilient lever arm 43 . Resilient member 36 is maintained in proximal relations to a barrier 45 , such that attaching member 34 is maintained in axial alignment described above.
Now referring to FIGS. 6 , 8 , and 10 , the interior of first half 22 is illustrated having a reinforcement means 46 defining opening 42 . Reinforcement means 46 extends inwardly but does not interfere with the sliding action of attaching member 34 on first and second tracks 30 and 32 . At least a first ridge 48 extends inwardly from the interior of first half 22 and is in proximal relation to first track 30 . In a preferred embodiment, a second ridge 50 also extends inwardly from the interior of first half 22 and is in proximal relation to second track 32 . Ridges 48 and 50 prevent upward movement of attaching member 34 , yet do not interfere with the sliding arrangement of attaching member 34 over first and second tracks 30 and 32 . Ridges 48 and 50 are in substantially parallel relations to one another.
Now referring to FIG. 12 and FIGS. 11 and 11A again in particular, in addition to the previous FIGS, a plurality of devices has been provided to prevent unauthorized manipulation and disengagement of attaching member 34 . When first half 22 and second half 24 are assembled, a shaft 52 , having a plurality of indentations 54 at predetermined intervals along the length thereof, is inserted through hole 42 and is received securely yet removably within opening 38 of attaching member 34 . Shaft 52 further extends into aperture 40 , which is defined by a tubular formation 41 extending inwardly from second half 24 . A top 55 is securely maintained at one end of shaft 52 , such that an opposing end of shaft 52 traverses an article to be monitored and is maintained within opening 38 of attaching member 34 and aperture 40 , whereby the article is securely bound between top 55 and outer surface of tag 20 .
Now also referring to FIGS. 12A , 12 B, and 12 C, attaching member 34 has a forward edge 75 and a distal rearward edge 77 . An attaching region 78 is defined proximal to the forward edge 75 and resilient member 36 is located proximal to rearward edge 77 . A first region 80 and a second region 82 are divided by attaching region 78 . A first lip 84 extends downwardly from first region 80 and a second lip 86 extends downwardly from second region 82 , such that first lip 84 and second lip 86 are in substantially parallel relations to one another, and each of the lips 84 and 86 are in substantially perpendicular relation to first and second regions 80 and 82 respectively. A first interior wall 88 and a second interior wall 90 are created by lips 84 and 86 respectively. First lip 84 and second lip 86 extend beyond rearward edge 77 and form a first outward curve 92 and a second outward curve 94 respectively, on a side of attaching member 34 proximal to resilient member 36 . Opening 38 of attaching member 34 is defined by a first jaw 96 and an opposing second jaw 98 . Jaws 96 and 98 extend downwardly from the plane of first and second regions 80 and 82 and are in proximal relations when they define opening 38 . However, jaws 96 and 98 are flexible such that they can move towards one another to decrease the size of opening 38 or they can move away from one another to increase the size of opening 38 . As a result, shaft 52 is maintained within opening 38 as defined by jaws 96 and 98 in a secure, yet removable, manner.
Now also referring to FIG. 12D , first track 30 has a first top edge 100 and a first bottom edge 104 which are distal to one another and are interconnected by a first front edge 108 and an opposing first back edge 112 . Second track 30 has a second top edge 102 and a second bottom edge 106 which are distal to one another and are interconnected by a second front edge 110 and an opposing second back edge 114 . First back edge 112 and second back edge 114 are curved to accommodate the curved portion of second side wall 28 where apex 25 is created. First track 30 has a first outer surface 116 and a first inner surface 120 and second track 32 has a second outer surface 118 and a second inner surface 122 .
In order to disengage shaft 52 from jaws 96 and 98 , enough force must be applied to forward edge 75 of attaching member 34 to overcome the force exerted by the resilient member 36 , and to move attaching member 34 towards rearward edge 75 . In addition, the force must be sufficient to overcome the frictional force created between first interior wall 88 and second outer surface 118 and the frictional force created between second interior wall 90 and first outer surface 116 . In order to do so, a probe 8 of a predetermined shape and length must be inserted through entrance 56 of tag 20 and extend to attaching member 34 to apply the sufficient necessary force to forward edge 75 to overcome the force exerted by the resilient member 36 and the frictional force described above to allow sufficient linear movement along first and second tracks 30 and 32 to disengage and remove shaft 52 from first and second jaws 96 and 98 . U.S. Pat. No. 4,738,258 is hereby incorporated by reference for teaching the probe 8 required and the necessary actuation thereof for insertion into entrance 56 . U.S. Pat. No. 4,738,258 can be modified into the disengagement apparatus illustrated in U.S. Pat. Nos. 5,426,419 and 5,535,606, the teachings of the detachers are also incorporated herein by reference.
To determine the force required to disengage the shaft 52 from jaws 96 and 98 of attaching member 34 of the instant invention as compared to the tag of the '419 patent, the following experiment was conducted on ten tags 10 of the instant invention and ten tags produced in accordance with the specification of the '419 patent. A spring balance was hung on a wall, with its spring loading hook at the bottom. Two ends of a cotton sling were tied to form a loop. One end of the loop was secured on the hook of the balance whereas the other end was wound through the handle such that a downward pull force on the detacher (as illustrated in FIGS. 11 and 12 of the '419 patent) led to the squeezing of the detacher's trigger. Because the spring balance is in series with the sling, a measure of the triggering force to detach the tack shaft 52 could be measured. On average, approximately five pounds more force was required to detach the shaft 52 from the attaching member 34 of the instant invention than the tag of the '419 patent.
In order to defeat the introduction of unauthorized probes into entrance 56 , several false paths and barriers are provided within tag 20 and the arcuate channel of the '419 patent and the '390 patent are completely eliminated. Because apex region 25 of tag 20 is constructed to be securely retained within a nesting or cradle area of a detacher, as taught by the '419 patent, tag 20 does not require any arcuate channels to lead the detaching probe 8 to the forward edge 75 of the attaching member 34 . The predetermined shape of the detaching probe 8 and the predetermined positioning of the attaching member 34 allow an authorized individual using an authorized detacher to disengage the shaft 52 from jaws 96 and 98 , thereby releasing the attached article. Dashed line 99 , of FIG. 5 , illustrates a proper path that may be taken by the detaching probe 8 .
However, to defeat even the introduction of a probe that has been illicitly disassembled from an authorized detacher, a first partition 58 prevents entrance of the unauthorized probe if at an incorrect plane. A second partition 60 having a greater height than first partition 58 , also prevents the introduction of an unauthorized probe to attaching member 34 . A first pillar 62 and a second pillar 64 also prevent application of force to attaching member 34 by an unauthorized probe by deflecting the same. A third partition 66 , a fourth partition 68 , a fifth partition 70 , and sixth partition 72 are at different levels and define a plurality of cavities 74 therebetween. Cavities 74 extend within apex region 25 and are substantially perpendicular to the plane of attaching member 34 , such that an unauthorized probe inserted through apex region 25 will be retained within a single cavity 74 and will not be able to manipulate attaching member 34 laterally to disengage shaft 52 .
Furthermore, if an unauthorized probe is being manipulated by hand, the probe will not be inserted at the correct plane to make proper contact with forward edge 75 of attaching member 34 to disengage the same. Instead, the unauthorized probe will go into the space defined between attaching member 34 and the different partitions 66 , 68 , 70 , and 72 . FIGS. 13 and 13A teach an alternate preferred embodiment with different barriers to prevent access to the attaching member 34 of tag 20 . FIG. 14 and 14A teach an alternate preferred embodiment with further different barrier arrangements to prevent access to the attaching member 34 of tag 20 .
Referring now also to FIG. 15 , therein is illustrated a schematic diagram of a resonant tag circuit 124 . In a preferred embodiment, circuit 124 has at least an inductive element 126 and at least a capacitance element 128 connected in a series loop and forming an inductive capacitance (LC) resonant circuit 124 . The resonant tag circuit is employed in connection with electronic article security systems particularly electronic article security systems of the radio frequency or RF electromagnetic field type. Such electronic article security systems are well known in the art and a complete detailed description of the structure and operation of such electronic article security systems is consequently not necessary for an understanding of the present invention.
However, as illustrated in FIG. 17 , such electronic article security systems employing resonant tag circuits include a transmitting means 130 for transmitting electromagnetic energy at or near the resonant frequency of the resonant tag into or through a surveillance zone 132 . A detecting means 134 monitors the surveillance zone 132 for the presence of a resonant tag within the surveillance zone 132 . Surveillance zone 132 is generally proximate to an entrance and/or exit of a facility such as, but not limited to, a retail store. The security system's function is to detect the presence within the surveillance zone 132 a monitored article having a resonant tag circuit 124 attached thereto in a secure fashion.
In such a system, transmitting means 130 transmits pulses in the form of RF bursts at a frequency in the low radio-frequency range, such as 58 kHz in a preferred embodiment but may be adapted to be at any appropriate frequency as desired. The pulses (bursts) are emitted (transmitted) at a repetition rate of, for example 60 Hz AC cycle, with a pause between successive pulses. The detecting means 134 includes a receiver 136 which is synchronized (gated) with the transmitting means 130 so that it is activated only during the pauses between the pulses emitted by the transmitting means 130 . The receiver 136 expects to detect nothing in these pauses between the pulses. If an activated tag is present within the surveillance zone 132 , however, the resonator therein is excited by the transmitted pulses, and will be caused to oscillate at the transmitter frequency, i.e., at 58 kHz in the above example. The resonator emits a signal which rings at the resonator frequency, with an exponential decay time (“ring-down time”). The signal emitted by the activated tag, if it is present between transmitting means 130 and the receiver 136 , is detected by the receiver 136 in the pauses between the transmitted pulses and the receiver accordingly triggers an alarm 138 . Alarm 138 may be audible and/or visual or can be a silent alarm that is detected by any means known in the art.
In a preferred embodiment, to minimize false alarms, the detecting means 134 usually must detect a signal in at least two, and preferably four, successive pauses; however, it is to be understood that the present invention can be adapted to function within one pause. Furthermore, in order to further minimize false alarms, such as due to signals produced by other RF sources, the receiver 136 employs two detection windows within each pause. The receiver 136 integrates any 58 kHz signal (in this example) which is present in each window, and compares the integration results of the respective signals integrated in the windows. Since the signal produced by the tag is a decaying signal, if the detected signal originates from a resonator in a tag it will exhibit decreasing amplitude (integration result) in the windows. By contrast, an RF signal from another RF source, which may coincidentally be at, or have harmonics at, the predetermined resonant frequency, would be expected to exhibit substantially the same amplitude (integration result) in each window. Therefore, alarm 138 is triggered only if the signal detected in both windows in a pause exhibits the aforementioned decreasing amplitude characteristic in each of a number of successive pauses.
For this purpose, as noted above, the receiver electronics is synchronized by a synchronization circuit with the transmitter electronics. The receiver electronics is activated by the synchronization circuit to look for the presence of a signal at the predetermined resonant frequency in a first activation window of about 1.7 ms after the end of each transmitted pulse. For reliably distinguishing the signal (if it originated from the resonator) integrated within this first window from the signal integrated in the second window, a high signal amplitude is desirable in the first window. Subsequently, the receiver electronics is deactivated, and is then re-activated in a second detection window at approximately 6 ms after the original resonator excitation, in order to again look for and integrate a signal at the predetermined resonant frequency. If such a signal is integrated with approximately the same result as in the first detection window, the evaluation electronics assumes that the signal detected in the first window did not originate from a marker, but instead originated from noise or some other external RF source, and alarm 138 therefore is not triggered.
Now also referring to FIGS. 16 and 18 , therein is illustrated a preferred embodiment of the resonant tag circuit 124 . Inductive element 126 is formed by a conducting member 140 that is made of any material that is capable of conducting electricity, and in a preferred embodiment is made of copper. Conducting member 140 is coiled around a first member 142 that is preferably constructed of a non-conductive material such as, but not limited to, plastic and rubber. First member 142 has a first wall 144 and a second wall 146 that are interconnected by a middle portion 148 . First wall 144 , second wall 146 , and middle portion 148 axially define a cavity 150 extending therethrough.
Middle portion 148 is adapted to receive conducting member 140 thereon in a coiled fashion on an outer surface 152 thereof between first wall 144 and second wall 146 . Middle portion 148 has an inner surface 154 that defines cavity 150 . A magnetic member 156 is adapted to be received within cavity 150 and to be frictionally retained within inner surface 154 of middle portion 148 . Magnetic member 156 may be a ferromagnetic material or any other material having magnetic properties, and in a preferred embodiment, magnetic member 156 is made of amorphous metals.
Capacitance element 128 is a parallel plate capacitor formed of conductive material on a first plate and a second plate (not shown) that are known in the art. Capacitance element 128 is adapted to be received on first member 142 , and in a preferred embodiment is received on first wall 144 thereof. First plate and second plate of capacitance element 128 are attached to opposing ends of conducting member 140 to form a series circuit.
When resonant tag circuit 124 enters a surveillance zone 132 it is subjected to an electromagnetic field and magnetic member 156 is charged. As the electromagnetic field is removed, the stored magnetic energy stored in the magnetic member 156 is released and thus an ac current is generated within inductive element 126 and capacitance element 128 . When an ac voltage is applied to the resonant tag circuit 124 , the current depends on the frequency thereof. The resonant frequency of circuit 124 can be determined by the following equation:
fo
=
1
2
π
LC
Wherein f 0 is the resonant frequency of the circuit and L is the inductance and C is the capacitance. As can be ascertained from the equation, many possible combinations yield the desired resonant frequency, however, the L to C ratio is preferably kept high in order for the circuit to be selective and minimize undesirable resonances to disturbances close to the resonant frequency thus minimizing false alarms. In a preferred embodiment, optimal values were determined to be L=2.08 mH and C=3.6 nF thus yielding an L to C ratio of 577,777.78.
It is to be understood that resonant tag circuit 124 is of sufficient size to be stored within casings used in article surveillance systems. Specifically, tag circuit 124 is of sufficient size to be received and enclosed within compartment 76 of tag 20 . Compartment 76 is defined by a peripheral wall 158 extending inwardly from second half 24 to enclose the resonant tag circuit 124 therein. A false path 160 is created between second side wall 28 and peripheral wall 158 .
If an article having resonant tag circuit 124 attached thereto via tag 20 is moved into the surveillance zone 132 , the alarm 138 will be activated by circuit 124 to signify unauthorized removal of the article through a specified area. For purposes of illustration but not limitation, in a preferred embodiment, the length of circuit 124 is less than 2 cm and the radius thereof is less than 1 cm. However, it is to be understood that alternate sizes and shapes of circuit 124 will also function as taught and alternate electronic detection circuits as are known in the art may also be used.
Now also referring to FIGS. 5 , 5 A, 5 B and 5 C, unscrupulous individuals have taken a garment protected by tag 20 into a dressing room of a retail location and used tools, such as hand held cutters, to sever the body of the tag 20 to remove and discard the resonant tag circuit 124 in the dressing room. The unscrupulous individuals are then able to abscond with the garment with the shaft 52 and attaching member 34 attached to the garment without setting off the electronic detection circuit. In the safety of their own home, the unscrupulous individual has the necessary time and larger equipment to manipulate the attaching member 34 to disengage the shaft 52 from the garment.
At least one vial 170 is positioned within first half 22 and second half 24 such that it does not interfere with the movement of attaching member 34 . The vial 170 is known in the art and is preferably made of breakable glass which can be modified to break at a predetermined pressure application. Vial 170 contains a heavily staining and/or ill-smelling substance, preferably a liquid or gas under pressure, which is able to adhere durably to article to which tag 20 is attached, thereby rendering the article unusable. If an unauthorized person attempts to cut tag 20 or uses force to disengage the pin from the article being monitored, vial 170 will break causing said staining and/or ill-smelling substance to be expelled onto the article. To aid in the expulsion of the staining and/or ill-smelling substance, at least an orifice 172 is defined through first half 22 and second half 24 .
To prevent unauthorized insertions of foreign objects through orifice 172 , vial 170 can be positioned within first half 22 and second half 24 to occlude orifice 172 . Vial 170 may be maintained in position by frictional engagement, adhesive, or resilient protrusions that extend inwardly from either first half 22 or second half 24 and firmly engage vial 170 therebetween. In one preferred embodiment, vial 170 is frictionally maintained within false path 160 between second side wall 28 and peripheral wall 158 . Vial 170 , however, may also be positioned in other desirable locations as illustrated in the figures to prevent the cutting of the body of tag 20 . Vial 170 is positioned to cover an area 173 between the resonant tag circuit 124 and the attaching member 134 .
Now referring to FIG. 13 A, in order to increase the susceptibility of the vial 170 to breakage, a pressure point 174 extends inwardly from either first half 22 or second half 24 and engages a portion of vial 170 . Thereby, an application of force to the outside of tag 20 by unauthorized tools will force pressure point 174 toward vial 170 and cause breakage thereof and expulsion of the staining or ill-smelling fluid or substance.
While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible without departing from the essential spirit of this invention. Accordingly, the scope of the invention should be determined not by the embodiment illustrated, but by the appended claims and their legal equivalents. | An electronic article surveillance (EAS) tag having an attaching member 34 located therein and adapted to securely and releasably receive a shaft of a pin therein, whereby a predetermined arcuate probe is inserted through an opening and applies a requisite force to the attaching member to release the shaft. At least one frangible vial containing a detrimental substance positioned within the tag body to deter unauthorized manipulation of the tag. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2014-0108569 filed on Aug. 20, 2014, with the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to a non-contact type power receiving apparatus capable of charging a battery with power by receiving the power in a non-contact scheme.
[0003] An electronic apparatus is operated using electricity as an energy source.
[0004] Electrical power, an energy source, needs to be supplied to operate an electronic apparatus. Such an electronic apparatus may be driven with power generated through self power generation or receive externally supplied power.
[0005] In order for the electronic apparatus to receive the externally supplied power, a power supplying apparatus for transferring the power from an external power supplying facility to the electronic apparatus is required.
[0006] As the power supplying apparatus, generally, a contact type power supplying apparatus directly connected to the electronic apparatus by a connector, or the like, is used to supply power to a battery embedded in the electronic apparatus. Alternatively, power may be supplied to the battery embedded in the electronic apparatus in a non-contact scheme as in the following Related Art Document.
[0007] Meanwhile, rated voltages of the battery may be different from each other for each electronic apparatus. Circuit configurations of the non-contact type power receiving apparatus may be different from each other for each rated voltage of the battery. It may be difficult to use a circuit in common. Therefore, manufacturing costs may be increased.
SUMMARY
[0008] An aspect of the present disclosure may provide a non-contact type power receiving apparatus in which a voltage level of output power is varied depending on a rated voltage of a battery.
[0009] According to an aspect of the present disclosure, a non-contact type power receiving apparatus may include: a power receiving coil unit receiving power in a non-contact scheme; a rectifying/multiplying unit rectifying the received power depending on controlling thereof and selectively multiplying a voltage level of the rectified power; and a controlling unit selectively controlling a rectifying operation or a multiplying operation of the rectifying/multiplying unit to be performed depending on a selection signal.
[0010] According to another aspect of the present disclosure, a non-contact type power receiving apparatus may include: a power receiving unit outputting one of a first power generated by rectifying power received in a non-contact scheme and a second power generated by rectifying and multiplying the power depending on a selection signal; and a battery providing the selection signal depending on a preset rated voltage to thereby be charged with power corresponding to the rated voltage, of the first power and the second power.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The above and other aspects, features and other advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 is a schematic block diagram of a non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure;
[0013] FIGS. 2A and 2B are block diagrams schematically illustrating a selective operation of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure;
[0014] FIG. 3 is a flow chart sequentially illustrating operations of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure;
[0015] FIG. 4A is a circuit diagram of a power receiving coil unit and rectifying/multiplying unit of FIG. 1 according to an embodiment of the present disclosure. FIG. 4B illustrates a switching operation of the circuit of FIG. 4A . FIG. 4C is a circuit diagram of a power receiving coil unit and rectifying/multiplying unit of FIG. 1 according to another embodiment of the present disclosure. FIG. 4D illustrates a switching operation of the circuit of FIG. 4 C.;
[0016] FIGS. 5A and 5B are circuit diagrams illustrating a rectifying operation of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure;
[0017] FIGS. 6A and 6B are circuit diagrams illustrating a multiplayer operation of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure;
[0018] FIGS. 7A and 7B are circuit diagrams illustrating a multiplying operation of a non-contact type power receiving apparatus according to another exemplary embodiment of the present disclosure;
[0019] FIGS. 8A and 8B are circuit diagrams illustrating a multiplying operation of a non-contact type power receiving apparatus according to another exemplary embodiment of the present disclosure; and
[0020] FIGS. 9A and 9B are circuit diagrams illustrating a multiplying operation of a non-contact type power receiving apparatus according to another exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
[0021] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.
[0022] The disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
[0023] In the drawings, the shapes and dimensions of elements maybe exaggerated for clarity, and the same reference numerals will be used throughout to designate the same or like elements.
[0024] FIG. 1 is a schematic block diagram of a non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure.
[0025] Referring to FIG. 1 , the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure may include a power receiving unit 110 and a battery 120 .
[0026] The power receiving unit 110 may vary a voltage level depending on a selection signal from the battery 120 and provide a first power or a second power to the battery 120 .
[0027] The power receiving unit 110 may include a power receiving coil unit 111 , a rectifying/multiplying unit 112 , a converter 113 , and a controller 114 .
[0028] The power receiving coil unit 111 may receive power from the outside in a non-contact scheme.
[0029] Here, the non-contact scheme may mean a scheme in which a direct connection is not made between conductors of a transmit side and a receive side in a process of transmitting power from the transmit side to the receive side and may be called a contactless scheme, a wireless transmitting scheme, or the like.
[0030] The rectifying/multiplying unit 112 may perform a rectifying operation or rectifying and multiplying operations depending on controlling of the controller 114 and transfer rectified power or power that is rectified and has a multiplied voltage level to the converter 113 .
[0031] The converter 113 may convert the power from the rectifying/multiplying unit 112 into charging power and transfer the charging power to the battery 120 .
[0032] The battery 120 may provide the selection signal to the controller 114 depending on its rated voltage, and the controller 114 may control an operation of the rectifying/multiplying unit 112 depending on the selection signal of the battery 120 to control the rectifying operation or the rectifying and multiplying operations to be performed.
[0033] FIGS. 2A and 2B are block diagrams schematically illustrating a selective operation of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure.
[0034] Referring to FIG. 2A together with FIG. 1 , data lines D+ and D− may be electrically connected between the power receiving unit 110 and the battery 120 to control an operation of the rectifying/multiplying unit 112 or the converting unit 113 depending on a charging state of the battery 120 to control the charging power transferred to the battery 120 .
[0035] Here, in the case in which a separate signal is not present from the battery 120 , the charging power having a preset voltage level, for example, 5V may be provided.
[0036] Referring to FIG. 2B , in the case in which a rated voltage of the battery 120 is different from a voltage level of a first charging power, the battery 120 may transfer the selection signal through the data lines D+ and D−.
[0037] For example, in the case in which the voltage level of the first charging power is 5V and the rated voltage of the battery 120 is 9V, the power receiving unit 110 may provide a second charging power having a voltage level of 9V, which is different from that of the first charging power, to the battery 120 depending on a selection signal form the battery 120 . The selection signal maybe generated depending on voltage levels applied to the data lines D+ and D−. For example, when the data line D+ has a voltage level of 3.3V and the data line D− has a voltage level of 0.6V, the selection signal maybe generated.
[0038] On the other hand, even in the case in the charging power charged in the battery 120 is 9V, when the rated voltage of the battery 120 is 9V, the selection signal may be provided, and a voltage level of the charging power charged in the battery 120 may be maintained.
[0039] FIG. 3 is a flow chart sequentially illustrating operations of the non-contact type power receiving apparatus according to an exemplary embodiment of the present disclosure.
[0040] A flow chart of the operations of the non-contact type power receiving apparatus described above with reference to FIGS. 1 through 2B is shown in FIG. 3 .
[0041] That is, the power receiving unit 110 may provide the first charging power having a first voltage to the battery 120 (S 10 ). Then, when the selection signal is input from the battery 120 to the power receiving unit 110 (S 20 ), the rectifying/multiplying unit 112 perform the multiplying operation, such that the power receiving unit 110 may provide the second charging power having a second voltage higher than the first voltage to the battery 120 (S 40 and S 50 ).
[0042] On the other hand, when the selection signal is not input from the battery 120 to the power receiving unit 110 , the first charging power may be maintained.
[0043] The charging power having a set voltage level may be provided to the battery 120 , such that the charging may be performed (S 60 ), and the charging may be performed until the charging of the power in the battery 120 is completed (S 70 ). FIG. 4A is a circuit diagram of a power receiving coil unit and rectifying/multiplying unit of FIG. 1 according to an embodiment of the present disclosure. FIG. 4B illustrates a switching operation of the circuit of FIG. 4A . The specification does not explain what is VP2 in the present FIG. 4A . FIG. 4C is a circuit diagram of a power receiving coil unit and rectifying/multiplying unit of FIG. 1 according to another embodiment of the present disclosure. FIG. 4D illustrates a switching operation of the circuit of FIG. 4C .
[0044] Referring to FIG. 4A , the power receiving coil unit 110 may include a power receiving coil CR 1 and a capacitor CD 1 .
[0045] The power receiving coil CR 1 may receive power from an external power transmitting coil in a non-contact scheme, and the capacitor CD 1 may block a direct current (DC) component of the power received in the power receiving coil CR 1 so as not to be transferred to the rectifying/multiplying unit 112 . In addition, a capacitance of the capacitor CD 1 may form LC resonance with an inductance of the power receiving coil CR 1 and form a resonant frequency to receive the power at the resonant frequency at the time of receiving the power, wherein the resonant frequency may be varied.
[0046] The rectifying/multiplying unit 112 may include a plurality of switches differently setting transfer paths of the power depending on controlling of the controlling unit 114 .
[0047] For example, the rectifying/multiplying unit 112 may include first to fourth switches S 1 to S 4 , wherein the first switch S 1 and the fourth switch S 4 may be connected to each other in series and the third switch S 3 and the second switch S 2 may be connected to each other in series.
[0048] The first switch S 1 and the fourth switch S 4 may be connected in parallel with the third switch S 3 and the second switch S 2 .
[0049] One end of the capacitor CD 1 may be connected to a connection point between the first switch S 1 and the fourth switch S 4 , and the other end of the capacitor CD 1 may be connected to one end of the power receiving coil CR 1 .
[0050] A connection point between the third switch S 3 and the second switch S 2 may be connected to the other end of the power receiving coil CR 1 .
[0051] At the time of performing the rectifying operation depending on the controlling of the controlling unit 114 , an operation of switching on the first and second switches S 1 and S 2 and switching off the third and fourth switches S 3 and S 4 and an operation of switching off the first and second switches S 1 and S 2 and switching on the third and fourth switches S 3 and S 4 may be alternately performed.
[0052] FIGS. 5A and 5B are circuit diagrams of the receiving coil unit and the rectifying/multiplying unit of FIG. 1 according to an example of the present disclosure.
[0053] Referring to FIGS. 5A and 5B , since power received in the power receiving coil CR 1 is an alternating current (AC) power, the first and second switches S 1 and S 2 may be switched on and the third and fourth switches S 3 and S 4 may be switched off in a positive half period of the AC power and the first and second switches S 1 and S 2 may be switched off and the third and fourth switches S 3 and S 4 may be switched on in a negative half period of the AC power to rectify the received power and transfer the rectified power to the converting unit 113 .
[0054] Meanwhile, referring to FIG. 4B , for example, the first and fourth switches S 1 and S 4 may be alternately switched on or off in order to perform the rectifying and multiplying operation depending on the controlling of the controlling unit 114 . In this case, the second switch S 2 may be maintained in a switched-on state and the third switch S 3 may be switched off. The above-mentioned alternate switching operation and switched-on or switched-off state maintaining operation may be variously set in each switch, which will be described with reference to FIGS. 6A through 9B .
[0055] FIGS. 6A and 6B are circuit diagrams of the receiving coil unit and the rectifying/multiplying unit of FIG. 1 according to another example of the present disclosure.
[0056] Referring to FIGS. 6A and 6B , the first switch S 1 may be maintained in a switched-on state, the fourth switch S 4 may be maintained in a switched-off state, and the third and second switches S 3 and S 2 may be alternately switched on/off, depending on the controlling of the controlling unit 114 .
[0057] Referring to FIG. 6A , the third switch S 3 may be switched on, such that electric charges of the received power may be charged in the capacitor CD 1 , and referring to FIG. 6B , the second switch S 2 may be switched on, such that a transfer path of the electric charges charged in the capacitor CD 1 may be formed, whereby a voltage level of the power transferred to the converting unit 113 may be multiplied.
[0058] FIGS. 7A and 7B are circuit diagrams of the receiving coil unit and the rectifying/multiplying unit of FIG. 1 according to another example of the present disclosure.
[0059] Referring to FIGS. 7A and 7B , the fourth switch S 4 may be maintained in a switched-on state, the first switch S 1 may be maintained in a switched-off state, and the second and third switches S 2 and S 3 may be alternately switched on/off, depending on the controlling of the controlling unit 114 .
[0060] Referring to FIG. 7A , the second switch S 2 may be switched on, such that the electric charges of the received power may be charged in the capacitor CD 1 , and referring to FIG. 7 B, the third switch S 3 may be switched on, such that a transfer path of the electric charges charged in the capacitor CD 1 may be formed, whereby a voltage level of the power transferred to the converting unit 113 may be multiplied.
[0061] FIGS. 8A and 8B are circuit diagrams of the receiving coil unit and the rectifying/multiplying unit of FIG. 1 according to another example of the present disclosure.
[0062] Referring to FIGS. 8A and 8B , the second switch S 2 may be maintained in a switched-on state, the third switch S 3 may be maintained in a switched-off state, and the fourth and first switches S 4 and S 1 may be alternately switched on/off, depending on the controlling of the controlling unit 114 .
[0063] Referring to FIG. 8A , the fourth switch S 4 may be switched on, such that the electric charges of the received power may be charged in the capacitor CD 1 , and referring to FIG. 8B , the first switch S 1 may be switched on, such that a transfer path of the electric charges charged in the capacitor CD 1 may be formed, whereby a voltage level of the power transferred to the converting unit 113 may be multiplied.
[0064] FIGS. 9A and 9B are circuit diagrams of the receiving coil unit and the rectifying/multiplying unit of FIG. 1 according to another example of the present disclosure.
[0065] Referring to FIGS. 9A and 9B , the third switch S 3 may be maintained in a switched-on state, the second switch S 2 may be maintained in a switched-off state, and the first and fourth switches S 1 and S 4 may be alternately switched on/off, depending on the controlling of the controlling unit 114 .
[0066] Referring to FIG. 9A , the first switch S 1 may be switched on, such that the electric charges of the received power may be charged in the capacitor CD 1 , and referring to FIG. 9B , the fourth switch S 4 may be switched on, such that a transfer path of the electric charges charged in the capacitor CD 1 may be formed, whereby a voltage level of the power transferred to the converting unit 113 may be multiplied.
[0067] As set forth above, according to exemplary embodiments of the present disclosure, one rectifying circuit may be used in common in batteries having two different rated voltages, such that a cost required for manufacturing the power receiving apparatus and a volume of the power receiving apparatus maybe decreased.
[0068] While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations could be made without departing from the scope of the present invention as defined by the appended claims. | A non-contact type power receiving apparatus, of which a voltage level of output power varies depending on a rated voltage of a battery, includes: a power receiving coil unit receiving a power in a non-contact scheme; a rectifying/multiplying unit rectifying the received power depending on controlling thereof and selectively multiplying a voltage level of the rectified power; and a controller selectively controlling a rectifying operation or a multiplying operation of the rectifying/multiplying unit to be performed depending on a selection signal. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a chain joint for link chains, having two identical, substantially U-shaped joint halves which are releasably connected to one another and each have an inner leg and an outer leg, the mutually facing sides of the inner and outer legs being connected to one another in the closed position of the joint by at least two in each case and at most four pairs of holding teeth in each case, and a supporting element for the joint halves being arranged between the mutually facing sides of the inner legs.
From German Patent Specification No. 1,901,367, a chain joint of the abovementioned type is known, wherein the inner and outer legs are connected to one another by two pairs of holding teeth formed with teeth of substantially the same thickness. It has been found that the strength of the known chain joint does not reach the desired values and that, inspite of the use of comparatively strong outer legs, the chain link breaks in the zone of the holding tooth of the outer leg, which is located most closely to the shackle base of the joint halves. If it is taken into account that the cross-section of the outer legs is greatest at the point of rupture, the conclusion can be drawn that stress peaks arise at the said point. Efforts to control the stress peaks by enlarging the cross-section of the outer legs had to be unsuccessful, if only because the dimensions of the chain joint must match the dimensions of the chain links belonging to the chain joint, that is to say because they must not differ too widely from the latter, in particular with respect to their external shape, since they must pass over the same chain wheels as the chain links. The indicated difficulties have had the result that chain joints of the generic type under discussion have been unable to gain acceptance in practice, inspite of numerous advantages.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a chain joint of the type under consideration, the strength of which is increased over that of known relevant chain joints by an improved distribution of the forces to be transmitted between the joint halves over the holding teeth. According to the invention this object is achieved when, in the case of two holding teeth per outer and inner leg, in each case the holding tooth, which is located most closely to the shackle base of the particular joint half, of the inner leg and the holding tooth, interacting with the former, of the outer leg and, in the case of three or four holding teeth per outer and inner leg, in each case the middle holding tooth or the two middle holding teeth of each leg are designed to be thicker than the holding teeth of the remaining pairs of holding teeth.
In the chain joint according to the invention, those holding teeth of thicker design which are regularly located most closely to the centre of the chain joint possess a greater rigidity than the other holding teeth. The consequence of the increased rigidity is that the proportion of the forces to be transmitted by the thicker holding teeth increases as compared with the forces to be transmitted by the remaining holding teeth. This leads to a relief even of those holding teeth of the outer legs which are located most closely to the shackle base of the chain joint halves and reduces the risk of premature ruptures at the abovementioned critical points.
An additional improvement in the force or stress conditions in the chain joint can be obtained when, with the chain joint unstressed, a clearance which can be reduced by the stress and which in practice is preferably 0.05-0.06 mm is present in each case between that holding tooth of the inner leg which is located most closely to the end of the inner leg and the associated holding tooth of the outer leg.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and features of the chain joint according to the invention can be seen from the sub-claims and the description below of several illustrative embodiments represented in the attached drawing, in which:
FIG. 1 shows a plan view of a chain joint having two pairs of holding teeth,
FIG. 2 shows a section along the libe II--II in FIG. 1,
FIG. 3 shows a detail of the chain joint according to FIGS. 1 and 2,
FIG. 4 shows a plan view of a chain joint having three pairs of holding teeth,
FIG. 5 shows a side view of the chain joint according to FIG. 4,
FIG. 6 shows a section along the line VI--VI in FIG. 4,
FIG. 7 shows, partially in section, a first side view of a supporting and locking element consisting of two parts and forming a pre-assembled unit,
FIG. 8 shows a second side view, offset by 90° relative to the side view according to FIG. 7, of the supporting and locking element according to FIG. 7,
FIG. 9 shows a view from below of the supporting and locking element according to FIGS. 7 and 8,
FIG. 10 shows a further supporting and locking element consisting of two parts and forming a pre-assembled unit,
FIG. 11 shows a detail of the chain joint according to FIGS. 4-6,
FIG. 12 shows a section along the line XII--XII in FIG. 11,
FIG. 13 shows a plan view of a chain joint having four pairs of holding teeth,
FIG. 14 shows a detail of the chain joint according to FIG. 13,
FIG. 15 shows a plan view of a modified chain joint having three pairs of holding teeth,
FIG. 16 shows a plan view of a further chain joint having three pairs of holding teeth,
FIG. 17 shows a section along the line XVII--XVII in FIG. 16,
FIG. 18 shows a plan view of a further chain joint having three pairs of holding teeth, and
FIG. 19 shows a section along the line XIX--XIX in FIG. 18.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, 1 and 2 mark two joint halves which have the same shape and each of which has an outer leg 3 and an inner leg 4. The outer legs 3 have two holding teeth 5 and 6, and the inner legs 4 have two holding teeth 7 and 8. As can be seen from the drawing, those holding teeth 7 of the inner leg 4 which are located most closely to the shackle base 9 of the joint halves 1 and 2 and the associated holding teeth 6 of the outer legs 3 are of thinner design than the other holding teeth 5 and 8. Therefore, the holding teeth 5 and 8 take up the main stress of the chain joint integrated into a chain strand.
The mutually facing sides 10 of the inner legs 4 are provided with engagement recesses 11, in which an expansion element 12 can engage which is designed as a tensioning sleeve and which is held in the locking position, that is to say in the engagement recesses, by a bolt-shaped, that is to say cylindrical, supporting element 13 which supports the holding teeth 5 and 8 which absorb the main stress.
As can be seen from FIG. 3, the holding teeth 5 and 8 have the same tooth height h and the same tooth thickness s 1i and s 1a . Similar comments apply to the weaker holding teeth 6 and 7, but the tooth thickness s 2i and s 2a of the latter is smaller than the tooth thickness of the holding teeth 5 and 8, at the same tooth height.
In the unstressed state of the chain joint, there is a small clearance a between the holding teeth 6 and 7, which clearance is reduced under stress and has the consequence that the holding teeth 6 and 7 are stressed only when forces are already being absorbed by the holding teeth 5 and 8.
FIG. 2 shows that the sides, facing the inner legs 4, of the outer legs 3 have a concave shape and the sides, facing the outer leg 3, of the inner legs 4 have a convex shape.
FIGS. 4-12 shows a chain joint which has proved to be particularly advantageous because of the use of three pairs of holding teeth.
Mutually corresponding or comparable parts of the second illustrative embodiment carry the same reference numerals as in the case of the first illustrative embodiment. Consequently, the joint halves are here also marked 1 and 2, and the inner and outer legs are marked 3 and 4. Each outer leg is provided with three holding teeth 14, 15 and 16, and each inner leg is provided with three holding teeth 17, 18 and 19. In the case shown, all the holding teeth have the same tooth height, but the tooth thickness of the holding teeth 15 and 18 is greater than the tooth thickness of the other holding teeth 16, 17 and 14, 19. In this illustrative embodiment also, a clearance a which fulfills the same purpose as in the first illustrative embodiment is present between the holding teeth 16 and 17.
A special feature of the second chain joint is that, in the latter, a pre-assembled unit consisting of an expansion element 20 and a supporting element 21 which here also has a cylindrical shape is used for locking the chain joint. As can be seen from FIGS. 7 and 8, the expansion element 20 is clamped onto a collar 22 of the supporting element 21. The collar 22 is adjoined by an oblique surface 23. FIG. 12 shows that the surfaces 10 of the inner legs are provided on one side of the engagement recess 11 with a set-back surface 24. The distance between the surfaces 24 of the mutually opposite inner legs is slightly greater than the diameter of the pre-assembled expansion element 20 before its final expansion by the supporting element 21. The pre-assembled unit formed by the supporting element 21 and the expansion element 20 can, in the region of the surfaces 24, be easily transferred into the engagement recess 11, and specifically for such a distance that the end face 25 of the expansion element 20 comes to bear against the shoulder 26 of the engagement recess 11. As soon as this position has been reached, the supporting element 21 is knocked into the expansion element 20, and perfect locking and support are obtained.
Whilst the collar 22 of the supporting element shown in FIGS. 7-9 has parallel side faces, FIG. 10 shows a pre-assembled unit consisting of an expansion element 27 and a supporting element 28, the collar 29 of which has likewise a fully cylindrical shape.
A chain joint having three pairs of holding teeth is particularly suitable in cases where the pitch t of the joint is greater than 3d and smaller than 4d, d being the diameter of the chain joint in the shackle zone or the diameter of the adjoining chain links not shown. The pitch t is defined as the maximum inner length of the chain joint as designated by the letter "t" in FIG. 4.
FIG. 13 shows a chain joint consisting of two joint halves 1 and 2, the outer legs 3 of which each have four holding teeth 30, 31, 32 and 33 and the inner legs 4 of which are likewise each provided with four holding teeth 34, 35, 36 and 37. In this case, the holding teeth 31 and 32 of the outer legs 3 and the holding teeth 35 and 36 of the inner legs 4 are of a thicker design than the other holding teeth. The main stress is thus taken up by the pairs 31, 36 and 32, 35 of holding teeth. A clearance a is again present between the holding teeth 33 and 34.
FIG. 15 shows a chain joint, in which the outer legs 3 and the inner legs 4 of each joint half 1 or 2 have again three holding teeth 38-40 or 41-43 respectively. In this case, the tips 44-46 of the holding teeth 38-40 are located on a circular arc. The same applies to the tips of the holding teeth 41-43 of the inner legs 4. The apex of the circular arc here points in each case towards the centre of the chain joint.
In the chain joints described so far, the holding teeth had substantially the same tooth height h, with different tooth thicknesses s. In FIG. 16, an illustrative embodiment of a chain joint is shown, in which the heights of the holding teeth are different. The outer legs 4 of the chain joint according to FIG. 16 have holding teeth 47-49, and the inner legs 3 have holding teeth 50-52. The pairs of holding teeth 48, 51 are in this case also thicker than the pairs of holding teeth 47, 52 and 49, 50, which are more remote from the centre of the chain joint. As can be seen, the tooth height h 1 of the holding teeth 48 and 51 is greater than the tooth height h 2 of the holding teeth 49 and 50.
The chain joint according to FIGS. 16 and 17 is locked by means of an expansion element 53 which is formed as a substantially U-shaped tensioning shackle with engagement legs 54 and 55. A supporting element 56 is arranged captively between the engagement legs 54 and 55 of the expansion element 53.
With respect to the design of its joint halves, the chain joint shown in FIGS. 18 and 19 corresponds largely to the chain joint according to FIGS. 4-6. It differs from the chain joint first described only by the type of locking chosen. Although the expansion element 57 is here also formed by a tensioning sleeve, securing is effected in this case by two supporting elements 58 and 59 which have the shape of wedges but which together again form a cylindrical support which is particularly advantageous for supporting the thicker holding teeth. | In a chain joint which consists of two identical, essentially U-shaped joint halves (1,2), the outer legs (3) and the inner legs (4) of the joint halves are provided with holding teeth (14-16 and 17-19 respectively). The holding teeth are here designed with unequal thickness, in such a way that certain pairs of holding teeth (15, 18) absorb a greater load than the other pairs of holding teeth (14,19,16,17). Due to the chosen arrangement, those zones of the outer legs (3) which are located most closely to the shackle base (9) of the joint halves (1,2) are noticeably relieved, and a premature rupture of the chain joint is prevented in this way. | 5 |
RELATED APPLICATIONS
This application is a continuation of and claims priority to U.S. patent application Ser. No. 11/719,816, filed Jul. 9, 2007, now U.S. Pat. No. 7,909,964 and entitled “Pulp Mould and Use of Pulp Mould,” which is a National Stage filing of and claims priority to international application PCT/SE2005/01771, filed on Nov. 25, 2005, which designated the United States and which was published in the English language on Jun. 1, 2006 as WO 2006/057609 A1, and which claims priority to Swedish patent application no. SE 0402899-9, filed Nov. 26, 2004. The entire content of each of the foregoing related applications are hereby fully incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a pulp mould for moulding three-dimensional pulp objects that can be used in a wide variety of applications. More specifically the objects are formed by using fibre slurry comprising a mixture of mainly fibres and liquid. The fibre slurry is arranged in the mould and part of the liquid is evacuated and a resulting fibrous object is produced.
BACKGROUND OF THE INVENTION
Packagings of moulded pulp are used in a wide variety of fields and provide an environmental friendly packaging solution that is biodegradable. Products from moulded pulp are often used as protective packagings for consumer goods like for instance cellular phones, computer equipment, DVD players as well as other electronic consumer goods and other products that need a packaging protection. Furthermore moulded pulp objects can be used in the food industry as hamburger shells, cups for liquid content, dinner plates etc. Moreover moulded pulp objects can be used to make up structural cores of lightweight sandwich panels or other lightweight load bearing structures. The shape of these products is often complicated and in many cases they have a short expected time presence in the market. Furthermore the production series may be of relative small size, why a low production cost of the pulp mould is an advantage, as also fast and cost effective way of manufacturing a mould. Another aspect is the internal structural strength of the products. Conventional pulp moulded objects have often been limited to packaging materials since they have had a competitive disadvantage in relation to products for example made of plastic. Moreover it would be advantageous to provide a moulded pulp object with a smooth surface structure.
In traditional pulp moulding lines, se for example U.S. Pat. No. 6,210,531, there is a fibre containing slurry which is supplied to a moulding die, e.g. by means of vacuum. The fibres are contained by a wire mesh applied on the moulding surface of the moulding die and some of the water is sucked away through the moulding die commonly by adding a vacuum source at the bottom of the mould. Thereafter the moulding die is gently pressed towards a complementary female part and at the end of the pressing the vacuum in the moulding die can be replaced by a gentle blow of air and at the same time a vacuum is applied at the complementary inversed shape, thereby enforcing a transfer of the moulded pulp object to the complementary female part. In the next step the moulded pulp object is transferred to a conveyor belt that transfers the moulded pulp object into an oven for drying. Before the final drying of the moulded pulp object the solid content (as defined by ISO 287) according to this conventional method is in around 15-20% and afterwards the solid content is increased to 90-95%. Since the solid content is fairly low before entering the oven, the product has a tendency of altering its shape and size due to shrinkage forces and furthermore structural tensions are preserved in the product. And since the shape and size has altered during the drying process it is often necessary to “after press” the product thereby enforcing the preferred shape and size. This however creates distortions and deformations deficiencies in the resulting product. Furthermore the drying process consumes high amounts of energy.
Conventional pulp moulds which are used in the above described process are commonly constructed by using a main body covered by a wire mesh for the moulding surface. The wire mesh prevents fibres to be sucked out through the mould, but letting the water passing out. The main body is traditionally constructed by joining aluminium blocks containing several drilled holes for water passage and thereby achieving the preferred shape. The wire mesh is commonly added to the main body by means of welding. This is however complicated, time consuming and costly. Furthermore the grid from the wire mesh as well as the welding spots is often apparent in the surface structure of the resulting product giving an undesirable roughness in the final product. Furthermore the method of applying the wire mesh sets restrictions of the complexity of shapes for the moulding die making it impossible to form certain configurations in the shape.
In EP0559490 and EP0559491 a pulp moulding die preferably comprising glass beads to form a porous structure is presented, which also mentions that sintered particles can be used. A supporting layer with particles having average sizes between 1-10 mm is covered by a moulding layer with particles having average sizes between 0.2-1.0 mm. The principle behind this known technology is to provide a layer wherein water can be kept by means of capillary attraction and by using the kept water to backwash the moulding die in order to prevent the fibres from clogging the moulding die. This process is however complicated.
U.S. Pat. No. 6,451,235 shows an apparatus and a method for forming pulp moulded objects using two steps. The first steps wet-forms a pre fibrous object which in the second step is heated and pressed under a large pressure. The pulp mould is formed of solid metal having drilled drainage channels to evacuate fluid.
U.S. Pat. No. 5,603,808 presents a pulp mould where one embodiment shows a porous base structure covered by a metal coating comprising squared openings of 0.1 mm to 2.0 mm.
U.S. Pat. No. 6,582,562 discloses a pulp mould capable of withstanding high temperature.
All prior art methods related to the production of a pulp mould, including the above disclosed methods, present some disadvantage.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a pulp mould that eliminates or at least minimizes some of the disadvantages mentioned above. This is achieved by presenting a pulp mould for moulding of objects from fibre pulp, comprising a sintered moulding surface and a permeable base structure where the moulding surface comprises at least one layer of sintered particles with an average diameter within the range 0.01-0.19 mm, preferably in the range 0.05-0.18 mm. This provides the advantage that the outermost layer of the moulding surface has fine structure with small pores in order to produce a pulp moulded object with a smooth surface and to contain fibres between a female and male mould preventing them from entering the same moulds and at the same time allowing fluid or vaporised fluid to emanate.
According to further aspects of the invention:
the pulp mould has a heat conductivity in the range of 1-1000 W/(m° C.), preferably at least 10 W/(m° C.), more preferred at least 40 W/(m° C.), which provide the advantage that heat can be transferred to the moulding surfaces during the press step in order for the press to be realised during increased temperature, which leads to a desirable vaporization of the fluid in pulp material. This vaporization helps the fluid to be sucked out throughout the moulds and helps the pressure to be equally distributed over the moulding surfaces and thus the moulded pulp becomes equally pressurised. the permeable base structure comprises sintered particles having average diameters that is larger than the particles in the moulding surface, preferably of at least 0.25 mm, preferably at least 0.35 mm, more preferably at least 0.45 mm and having average diameters less than 10 mm, preferably less than 5 mm, more preferred less than 2 mm, which provides the advantages with a base structure having a high fluid permeability to enable fluid and vapour to be evacuated from the moulded pulp and a base structure having a high an internal strength as to withstand the pressure imposed on the base structure during the pressing steps. a permeable support layer comprising sintered particles is arranged between the base structure and the moulding surface where particles of the support layer have average diameter less than the average diameter of the sintered particles in the base structure and larger than the average diameter of the sintered particles in the moulding surface, which provides the advantages that support layer can minimize voids in the moulds safeguarding that the moulding surface does not collapse into the voids and if the size difference between the sintered particles of the base structure and the sintered particles of the moulding surface is very large, the support layer is added to create a smooth transition from the small particles of the moulding layer to the larger particles of the base structure and thus so by using a particle sizes in between these two extremes, which minimizes voids created between layers of different sizes. the pulp mould has a total porosity of at least 8%, preferably at least 12%, more preferred at least 15% and that the pulp mould has total porosity of less than 40%, preferably less than 35%, more preferred less than 30%, which provides the advantage that liquid and vaporised liquid can emanate from the pulp mould. a heat source is arranged to supply heat to the pulp mould, which provides the advantage that the moulding surfaces can be heated during moulding. the bottom of the pulp mould is substantially flat and free of larger voids, arranged to transmit an applied pressure, which provides a surface suitable for heat transfer and provides the advantage of a form stable pulp mould. With larger voids is meant voids larger than the voids of the drainage channels, described below, for example a relief shaped pulp mould has a large void. a heat plate is arranged to the bottom of the mould and that the heat plate comprises suction openings, which provides the advantage that heat can be transferred to the pulp mould, thereby heating the moulding surface and that a source of suction can be arranged present a suction at the moulding surface. the pulp mould has at least one actuator arranged to its bottom, which provides the advantage that a female and a male pulp mould can be pressed together. the pulp mould is able to withstand temperature of at least 400° C., which provides the advantage that the mould can be heated to at least 400° C. during operation. the pulp mould contains at least one, preferably a plurality of drainage channels, which provides the advantage that drainage of fluid and vaporised fluid can be increased in the pulp mould. the drainage channel has a first diameter at the bottom of the pulp mould and a third diameter at the intersection between the base structure and the support layer, which is substantially smaller than the first diameter. the first diameter is larger than or equal to a second intermediate diameter and that the second diameter is larger than the third diameter. the second diameter is at least 1 mm, preferably at least 2 mm and that the third diameter is less than 500 μm, preferably less than 50 μm, more preferred less than 25 μm, most preferred less than 15 μm. the plurality of drainage channels are distributed in a distribution of at least 10 channels/m2, preferably 2500-500000 channels/m2, more preferred less than 40000 channels/m2, providing the advantage of good drainage capabilities. at least one pulp mould is arranged on the heat plate and that the heat plate has suction openings and that the suction openings are arranged to mate the plurality of drainage channels. during operation a male and a female pulp mould are pressed into contact and the temperature of the moulding surface is at least 200° C. transmitting heat to a mixture of fibres and liquid arranged between the female and male pulp mould, which provides the advantage that a large part of the liquid is vaporised and due to the expansion of the vapour the vaporised liquid emanates through the porous pulp moulds. Complex shapes of the mould can be constructed due to the use of sintering technique in manufacturing the moulds. The pulp moulds can be constructed using graphite or stainless steel sintering moulds. These sintering moulds are easily manufactured using conventional methods and can produce very complex shapes at a low cost and short manufacture time. The sintered mould of the invention can be manufactured with great precision. The sintered mould of the invention can be used 500000 times with preserved properties. The pulp mould may comprise one or more non-permeable surface areas containing said the sintered particles, the non-permeable surface area having a permeability that is substantially less than that of the moulding surface. If the sintered mould is outside the accuracy requirements it can be reformed by pressing the sintered mould in a second mould in which the sintered mould was created, without loss of characteristic features Surface structures on one or both sides of the pulp object can be created. For instance a logotype can be moulded at the bottom of a dinner plate. This can be done by adding a thin sintered layer with the shape of the logotype at one or both mouldings surfaces. A high internal strength in the resulting pulp moulded object can be produced using the pulp mould of the invention. Smooth surfaces on both sides are provided due to the fine accurate structure of the mouldings surfaces, combined with an ability to withstand high pressure and due to the heat conductivity making it possible to press using a high temperature at the moulding surfaces, enabling the liquid to be vaporised which will act as a cushion which smoothens any small inaccuracies in the moulding surfaces. Suction is evenly distributed due to the homogenous porosity of the mould. Pressure between the moulding surfaces becomes evenly distributed due too the cushion effect of the steam expansion and the evenly suction.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described in relation to the appended figures, wherein:
FIG. 1 shows a cross sectional view of a male part and complementary female part of a pulp mould according to a preferred embodiment of the present invention in a separate position,
FIG. 2 shows the same as FIG. 1 but in an a moulding position,
FIG. 2 a shows a zooming of a part of FIG. 2 ,
FIG. 2 ′ shows a pulp mould in a moulding position according to a second embodiment of the invention,
FIG. 2 a ′ shows a zooming of a part of FIG. 2 ′,
FIG. 3 shows a single drainage channel,
FIG. 4 is a cross sectional zooming of the male part of the pulp mould of FIG. 1 showing the moulding surface the tips of three drainage channels and the upper part of the base structure,
FIG. 5 is a cross sectional zooming of the female part of the pulp mould of FIG. 2 showing the moulding surface the tips of two drainage channels and the upper part of the base structure,
FIG. 6 is a cross sectional zooming of the embodiment shown in FIG. 3 showing the moulding surface and the upper part of the base structure,
FIG. 7 is a cross sectional zooming of the embodiment shown in FIG. 4 showing the moulding surface and the upper part of the base structure,
FIG. 8 shows a part of the moulding surface of the female and male pulp mould as seen from the forming space,
FIG. 9 shows a three-dimensional drawing of a pulp mould according to the present invention, and
FIG. 10 is an exploded view of a preferred embodiment of a mould combined with a heat and vacuum suction tool according to the invention.
DETAILED DESCRIPTION
FIG. 1 shows a cross-sectional view of a male 100 and a complementary female 200 part of a pulp mould according to a preferred embodiment of the present invention. Both the female 200 and the male 100 part are constructed according to the same principles. A forming space 300 is arranged between the pulp moulds 100 , 200 , where the moulded pulp is formed during operation. A base structure 110 , 210 constitutes the main bodies of the pulp mould 100 , 200 . A support layer 120 , 220 is arranged upon the base structure 110 , 210 . A moulding surface 130 , 230 is arranged upon the support layer 120 , 220 . The moulding surface 130 , 230 encloses the forming space 300 . A source for heating 410 (see FIG. 10 ), a source for suction 420 using underpressure and at least one actuator (not shown) to press the female mould 200 and the male mould 100 against each other are arranged at the bottom 140 , 240 of the base structure 110 , 210 . It is advantageous that the pulp moulds 100 , 200 have good heat conductive properties in order to transfer heat to the moulding surfaces 130 , 230 . It is advantageous that the base structure 110 , 210 is a stable structure being able to withstand high pressure (both applied pressure via the bottom 140 , 240 and pressure caused by steam formation within the mould) without deforming or collapsing and at the same time having throughput properties for liquid and vapour. More specific it is preferred that the throughput properties facilitate the drainage of liquid and vapour from the wet pulp mixture inside the forming space 300 during operation of the pulp mould 100 , 200 . It is therefore advantageous that the pulp mould has a total porosity of at least 8%, preferably at least 12%, more preferably at least 15% and at the same time to be able to withstand the operating pressure it is advantageous that the total porosity is less than 40%, preferably less than 35%, more preferably less than 30%. The total porosity is defined as the density of a porous structure divided by the density of a homogenous structure of the same volume and material as the porous structure. The throughput properties are increased by a plurality of drainage channels 150 , 250 . It is preferred that the plurality of drainage channels 150 , 250 are frusta conical and having a sharply pointed tip towards the intersection between base structure 110 , 210 and support layer 120 , 220 , e.g. the plurality of drainage channels 150 , 250 of the present embodiment has a nail form with the nail tip pointing towards the forming space 300 .
As is evident from FIG. 1 all parts of the mould 100 , 200 are applied with the fine particles that forms the support layer 130 , 230 . However, all parts of that surface are not used to form a pulp object, but there are peripheral surfaces 160 , 260 that will not be used to form a pulp object. As a consequence, these surfaces 160 , 260 preferably have a permeability that is substantially smaller than the moulding surfaces 130 , 230 . In the preferred embodiment this is achieved by applying a thin impermeable layer 161 , 261 having appropriate properties, e.g. any kind of paint having sufficient strength durability to maintain its impermeable function when used under operating conditions (high heat some vibration, pressure, etc.). Alternatively this impermeable layer 161 , 261 may be achieved by workshop machining techniques, for instance by applying a high pressure upon these surfaces 160 , 260 , to achieve a compacted surface layer 160 , 260 whereby the pores will be closed. Of course other methods of making these surfaces 160 , 260 impermeable can be used as long as the result yields an impermeable surface 160 , 260 .
In FIG. 2 , 2 a there is shown the position of the two mould halves 100 , 200 during the heat press forming action. As can be seen there is formed a forming space 300 between the mould surfaces 130 , 230 , that is about 0.8-1 mm, preferably in the range 0.5-2 mm. As can be the surfaces that will not be used to form a pulp object, 160 , 260 A has a thin impermeable layer 161 , 261 applied upon them. As can be seen in FIG. 2A the upper drainage channel 150 ends where the moulding surface 130 meets the forming space 300 and the lower drainage channel 250 ends between moulding surface 230 and support layer 220 . The drainage channels 150 , 250 can have its pointed ending anywhere in the interval from the border between the base structure 110 , 210 and the support layer 120 , 220 till the border between the moulding surface 130 , 230 and the forming space 300 .
In this connection it may be mentioned that possible protruding fibre lumps, protruding on top of the slope 260 A, may easily also be handled by the use of applying a water stream, e.g. by means of an appropriately formed water jet, that will fold the protruding lumps onto the moulding surface 230 being under vacuum, such that they adhere to the rest of the fibres web.
In FIG. 2 ′, 2 a ′ according to a second embodiment of the invention there is shown the position of the two mould halves 100 , 200 during the heat press forming action. As can be seen there is formed a forming space 300 between the mould surfaces 130 , 230 , that is about 1 mm, preferably in the range 0.5-2 mm. As also can be seen from FIG. 2 ′ the mating surfaces 161 , 261 of the mould halves 100 , 200 , do form a substantially smaller gap 300 ′ than the forming space 300 . The mating surfaces 161 , 261 is somewhat tilted to the left as is shown by the angle α in order to facilitate introduction of the male 100 into the female mould 200 . Also it can be seen that the bottom surface 140 of the male mould is above the level of the upper portion 260 A of the female mould, i.e. there is formed a gap between the support and heat plate 410 (see FIG. 10 ) of the male mould 100 and the female mould 200 , which is feasible thanks to the arrangement according to the inventive process where the applied pressure may be directly transferred to the pulp body, i.e. by means of the mould surfaces 130 , 230 . In other words normally there is no need for external abutting means (although they may be useful in some cases) to position the mould halves 100 , 200 during the pressing action. According to the embodiment shown in FIG. 2 ′ the design provides for using the relatively sharp edge between the horizontal surface 260 A and the vertical surface 261 to cut possible fibres lumps that protrude beyond the moulding surface 130 , 160 of the male mould 100 . As can be seen in FIG. 2 ′, 2 a ′ the plurality of drainage channels 150 , 250 is shown to end at the intersection between the moulding surface 130 , 230 and the forming space 300 . Depending of an actual embodiment of the invention the drainage channels 150 , 250 could have its pointed ending anywhere in the interval from the border between the base structure 110 , 210 and the support layer 120 , 220 till the border between the moulding surface 130 , 230 and the forming space 300 .
FIG. 3 shows a drainage channel 150 , 250 . The diameter Ø 1 is the diameter of the plurality of drainage channels 150 , 250 at the bottom 140 , 240 of the pulp moulds 100 , 200 . The main part 151 , 251 of the plurality of drainage channels 150 , 250 inclines slightly from the diameter Ø 1 towards the diameter Ø 2 . The relation between diameter Ø 1 and diameter Ø 2 is at least Ø 1 ≧Ø 2 and preferably Ø 1 >Ø 2 . Diameter Ø 2 is preferably above 2 mm, preferably 3 mm, i.e. preferably large enough to prevent capillary attraction. The form of the main portion t 1 of each drainage channel 150 , 250 is dependent of the thickness of the pulp mould 100 , 200 and therefore varies according to the desired shape of the pulp moulded object. The top portion t 2 of each drainage channel 150 , 250 has a diameter Ø 2 that preferably decreases sharply towards diameter Ø 3 , at the border between base structure 110 , 210 and support layer 120 , 220 . The diameter Ø 3 is preferably substantially zero and at least less than 500 μm preferably less than 50 μm, more preferably less than 25 μm, most preferably less than 15 μm. The relation between diameter Ø 2 and diameter Ø 3 is preferably Ø 2 >Ø 3 and most preferred Ø 2 >>Ø 3 . In the embodiment of FIG. 1 and FIG. 2 , Ø 2 was set to 3 mm, Ø 3 was set to 10 μm and the length t 2 of the top portion was set to 10 mm. If a drainage channel would have its tip in the border between the moulding surface 130 , 230 and the forming space 300 and meeting an inclination of the moulding surface 130 , 230 above 40° it may be an advantage to use a drainage channel 150 , 250 without a conical top, i.e. Ø 2 =Ø 3 , in order to ensure a pointed opening towards the forming space 300 . Another way to ensure a pointed opening towards the forming space 300 , when the moulding surface 130 , 230 has a steep inclination, is to increase the length t 2 of the top portion. If the drainage channels are arranged to have their tips in the border between the moulding surface 130 , 230 and the forming space 300 , the openings Ø 3 of the plurality of drainage channels 150 , 250 at the moulding surface 130 , 230 are preferably very small in order to prevent fibres contained in the forming space 300 from entering the pulp mould 100 , 200 , and also to produce a resulting surface structure of the pulp moulded object formed in the forming space 300 to be smooth. One of the reasons for the pointed tip of the plurality of drainage channels 150 , 250 is to prevent fluid from flowing back to the pulp moulded object after pressure and vacuum is released, due to the flow resistance created by the narrowing channel. Fibres from cellulose normally has an average length of 1-3 mm and an average diameter between 16-45 μm. Preferably the diameter of the drainage channels 150 , 250 increases gradually from the openings Ø 3 towards the diameter Ø 2 and further to the diameter Ø 1 of the drainage channels 150 , 250 . The plurality of drainage channels 150 , 250 of the embodiment of FIG. 1 and FIG. 2 was distributed with a distribution of 10000 channels/m 2 . Normally the distribution is in the interval of 100-500000 channels/m 2 and more preferred in the interval 2500-40000 channels/m 2 .
FIG. 4 and FIG. 5 are cross sectional zoomings of FIG. 1 and FIG. 2 respectively showing the moulding surface 130 , 230 , the support layer 120 , 220 , and the upper portion of the base structure 110 , 210 . As can be seen each drainage channel 150 , 250 penetrates the base structure 110 , 210 and has its pointed tip at the intersection between the base structure 110 , 210 and the support layer 120 , 220 . Depending of an actual embodiment of the invention the drainage channels 150 , 250 could have its pointed ending anywhere in the interval from the border between the base structure 110 , 210 and the support layer 120 , 220 till the border between the moulding surface 130 , 230 and the forming space 300 .
FIGS. 6 and 7 are cross sectional zoomings of FIG. 4 respectively FIG. 5 showing the moulding surface 130 , 230 , the support layer 120 , 220 and the upper part of the base structure 110 , 210 . As can be seen from the figures the moulding surface 130 , 230 comprises sintered particles 131 , 231 , having an average diameter 131 d , 231 d , provided in one thin layer. The thickness of the moulding surface is denoted by 133 , 233 and in the shown embodiment since the moulding surface 130 , 230 comprises one layer of particles the thickness 133 , 233 of the moulding surface 130 , 230 is equal to the average diameter 131 d , 231 d . Preferably sintered metal powder 131 , 231 with an average diameter 131 d , 231 d between 0.01-0.18 mm is used in the moulding surface 130 , 230 . (In the shown embodiment sintered metal powder 131 , 231 from Callo AB of the type Callo 25 was used to form the moulding surface 130 , 230 . This metal powder can be obtained from CALLO AB POPPELGATAN 15, 571 39 NÄSSJÖ, SWEDEN.) Callo 25 are spherical metal powder with a particle size range between 0.09-0.18 mm and a theoretical pore size of about 25 μm and a filter threshold of about 15 μm. As is evident for a skilled person in the field of powder metallurgy the particle size ranges includes smaller amounts of particles outside the ranges, i.e. up to 5-10% smaller respectively larger particles, this however has only marginal effects on the filtering process. The chemical composition of Callo 25 is 89% Cu and 11% Sn. As a way of example a sintered structure using Callo 25 and sintered to a density of 5.5 g/cm 3 and a porosity of 40 vol-%, would have about the following characteristics; tensile strength 3-4 kp/mm 2 , elongation 4%, coefficient of heat expansion 18·10 −6 , specific heat at 293 K is 335 J/(kg·K), maximum operative temperature in neutral atmosphere 400° C. Thus in the shown embodiment the thickness 133 , 233 of the moulding surface 130 , 230 is in the range 0.09-0.18 mm. Generally the moulding surface 130 , 230 comprises sintered particles 131 , 231 in at least one layer but most preferred in merely one layer. As can be seen from the figures the support layer 120 , 220 comprises sintered particles 121 , 221 , having an average diameter 121 d , 221 d.
The thickness of the support layer is denoted by 123 , 223 and in the shown embodiment, since the support layer 120 , 220 comprises one layer of particles, the thickness 123 , 223 of the support surface 120 , 220 is equal to the average diameter 121 d , 221 d . (In the shown embodiment sintered metal powder 121 , 221 from Callo AB of the type Callo 50 was used to form the support layer 120 , 220 . This metal powder can be obtained from CALLO AB POPPELGATAN 15, 571 39 NÄSSJÖ, SWEDEN.) Callo 50 are spherical metal powder with a particle size range between 0.18-0.25 mm and a theoretical pore size of about 50 μm and a filter threshold of about 25 μm. The chemical composition of Callo 50 is 89% Cu and 11% Sn. As a way of example a sintered structure using Callo 50 and sintered to a density of 5.5 g/cm 3 and a porosity of 40 vol-%, would have about the following characteristics; tensile strength 3-4 kp/mm 2 , elongation 4%, coefficient of heat expansion 18·10 −6 , specific heat at 293 K is 335 J/(kg·K), maximum operative temperature in neutral atmosphere 400° C. Thus in the shown embodiment the thickness 123 , 223 of the support layer 120 , 220 is in the range 0.18-0.25 mm. The support layer 120 , 220 may be omitted, especially if the size difference between the sintered particles 111 , 211 of the base structure 110 , 210 and the sintered particles 131 , 231 of the moulding surface 130 , 230 , is small enough, i.e. the function of the support layer 120 , 220 increase the strength of the mould, i.e. to safeguard that the moulding surface 130 , 230 does not collapse into the voids 114 , 214 , 124 , 224 . If the size difference between the sintered particles 111 , 211 of the base structure 110 , 210 and the sintered particles 131 , 231 of the moulding surface 130 , 230 , is very large, the support layer 120 , 220 can comprise several layers where the size of the sintered particles 121 , 221 gradually is increased in order to improve strength, i.e. to prevent structural collapse due to the voids between the layers.
The base structure 110 , 210 of the shown embodiment contains sintered metal powder 111 , 211 of the fabricate Callo 200 from the above mentioned Callo AB. Callo 200 is a spherical metal powder with a particle size range between 0.71-1.00 mm and a theoretical pore size of about 200 μm and a filter threshold of about 100 μm. The chemical composition of Callo 200 is 89% Cu and 11% Sn. As a way of example a sintered structure using Callo 200 and sintered to a density of 5.5 g/cm 3 and a porosity of 40 vol-%, would have about the following characteristics; tensile strength 3-4 kp/mm 2 , elongation 4%, coefficient of heat expansion 18·10 −6 , specific heat at 293 K is 335 J(kg·K), maximum operative temperature in neutral atmosphere 400° C. The pores 112 , 212 of the base structure 110 , 210 in the first embodiment has thus a theoretical pore size 112 d , 212 d of 200 μm, enabling liquid and vapour to be evacuated through the pore structure.
FIG. 8 shows a part of the moulding surface 130 , 230 as seen from the forming space 300 . The moulding surface 130 , 230 comprises sintered particles 131 , 231 having an average diameter of 131 d , 231 d . The pores 132 , 232 of the moulding surface 130 , 230 have a theoretical pore size 132 d , 232 d . In the above described embodiment the theoretical pore size 132 d , 232 d is about 25 μm. The pores 132 , 232 are preferably small enough in order to prevent cellulose fibres from entering the interior of the pulp mould 100 , 200 , but at the same time enabling liquid and vapour to be evacuated through the pores 132 , 232 . Fibres from cellulose normally have an average length of 1-3 mm and an average diameter between 16-45 μm.
FIG. 9 shows a three-dimensional drawing of a pulp mould 100 , 200 according to the present invention. The bottom opening Ø 1 of the plurality of drainage channels 150 of the male mould 100 are shown in the drawing. A source for heating, a source for suction using underpressure and at least one actuator to press the female mould 200 and the male mould 100 against each other can be arranged at the bottom 140 , 240 of the base structure 110 , 210 . For instance a heated metal plate can be used to transfer heat to the flat bottom 140 , 240 .
FIG. 10 is an exploded view of the heat and vacuum suction tool 400 of a preferred embodiment. A plurality of male pulp moulds 100 are arranged upon a support and heat plate 410 . Of course the same heat and vacuum suction tool 400 can be used to attach female pulp moulds 200 . The support and heat plate 410 is heated by means of induction. The support and heat plate 410 is divided into a plurality of locations 411 , where in the preferred embodiment up to eight pulp moulds 100 , 200 can be placed side by side. Of course the invention is by no means limited to this number, but it is rather depending outside production factors outside the scope of the present invention, i.e. the surface area of the support and heat plate 410 can be increased or decreased and/or the bottom area of the pulp mould 100 , could likewise be increased or decreased. The support and heat plate 410 comprises a plurality of suction openings 412 which are connected to the vacuum chamber 420 . Each male pulp mould 100 have its bottom side 140 being substantially flat, as mentioned below this may be achieved by machining. A machining action of a sintered porous surface will make the pore openings to clog. Thanks to the drainage channels 150 that will have no negative effect on the process, since sufficient throughput surface is achieved by the drainage openings despite the clogging of the pores at the bottom 140 of the pulp moulds 100 . On the contrary it will be shown that this is rather an advantage in the present invention. The support and heat plate 410 comprises a plurality of suction openings 412 and these are preferably arranged to mate the openings Ø 1 of the plurality of drainage channels 150 at the bottom of the pulp mould 100 . Since the bottom area between the drainage channels 150 is meeting the solid part of the support and heat plate 410 , no suction would have occurred through the pore openings 112 at the bottom surface 140 in this embodiment. The clogging of the pores 112 at the bottom surface 140 presents an advantage due to the fact that this area is in contact with the solid part of support and heat plate 410 and hence heat is better transferred to the clogged machined bottom surface 140 and thereby to the pulp mould 100 . The same principles of above will naturally yield for a female mould 200 attached to the heat and vacuum suction tool 400 . The vacuum chamber 420 is arranged at the bottom of the support and heat plate 410 . A plurality of spatial elements 421 are arranged to support the heat plate 410 and prevent the support and heat plate 410 from bend deformations due to the negative pressure in the vacuum chamber 420 . An isolation plate 430 is arranged to the bottom of the vacuum chamber 420 . The task appointed for the isolations plate 430 is to prevent heat from the support and heat plate 410 to transfer further to the process equipment. The isolation plate is preferably made of a material with low heat conductivity. A cooling element 440 is constructed from a first 441 and second 442 cooling plate. In the bottom side of the first cooling plate 441 and the front side of the second cooling plate 442 there is formed a machined cooling channel 443 having channel openings 443 a , 443 b . A fluid can flow into the cooling channel 443 or out from the cooling channel 443 through the channel openings 443 a , 443 b . The cooling channel 443 is formed in a meandering pattern from the first channel opening 443 a towards the second channel opening 443 b . To the bottom of the cooling element 440 there is arranged a plurality of attach devices 450 . These plurality of attach devices 450 are used for attaching the heat and vacuum suction tool 400 to a pressing tool (not shown in the drawing).
According to a preferred embodiment the pulp mould is produced in the following manner. For the sintering process a basic mould (not shown) is used as is known per se, e.g. made of synthetic graphite or stainless steel. The use of graphite provides a certain advantage in some cases, since it is extremely form stable in varying temperature ranges, i.e. heat expansion is very limited. On the other hand stainless steel may be preferred in other cases, i.e. depending on the configuration of the mould, since stainless steel has a heat expansion that is similar to the heat expansion of the sintered body (e.g. if mainly comprising bronze) such that during the cooling (after sintering) the sintered body and the basic mould contracts substantially equally. In the basic mould there is formed a moulding face that corresponds to the moulding surface 130 , 230 and also non-forming surfaces 160 , 260 of the pulp mould (that is to be produced), which moulding face may be produced in many different ways known in the art, e.g. by the use of conventional machining techniques. Since a very smooth surface of the pulp mould is desirable the finish of the surface of the moulding face should preferably be of high quality. However, the precision, i.e. exact measurement, must not be extremely high, since an advantage with the invention is that high quality moulded pulp products may be achieved even if moderate tolerances are used for the configuration of the pulp mould. As described above, the first heat pressing action (when producing a moulded pulp product according to the invention), creates a kind of impulse impact within the fibre material trapped in the void 300 between the two mould halves 100 , 200 , that forces the free liquid out of the web in a homogeneous manner, despite possible variations of web thickness, which as a result provides a substantially even moisture content within the whole web. Hence it is possible to produce the basic moulds with tolerances that allow cost efficient machining.
For the actual production of the pulp mould 100 , 200 the whole portion of the formed surface of the basic mould is arranged with an even layer of the very fine particles, that will form the surface 130 , 230 ; 160 , 260 of the pulp mould, which is performed by providing a thin layer to the basic mould that will adhere the particles 131 , 231 of the surface layer 130 , 230 ; 160 , 260 . This may be achieved in many different ways, for instance by applying a thin sticky layer (e.g. wax, starch, etc.) on to the basic mould, e.g. by means of spray or by applying it with a cloth. Once the sticky layer has been applied an excessive amount of the fine particles 131 , 231 (which form the surface layer of the pulp mould) are poured into the mould. By movement of the basic mould, such that the excessive amount of particles 131 , 231 move around onto every part of the surface within the basic mould, it is accomplished to arrange an even layer of the fine particles 131 , 231 on each part of the surface in the basic mould. This process may be repeated to achieve further layers, for instance the support layers 120 , 220 . In the next stage pointed elongated elements, e.g. nails, which preferably have a slightly conical shape, are arranged on top of the last layer. These objects will form enlarged drainage passages 150 , 250 in the basic body, which will facilitate an efficient drainage of fluid from the pulp web and providing a flow resistance hindering fluid to pour back. Thereafter further particles 111 , 211 are poured into the basic mould forming the basic body 110 , 210 of the pulp mould, on the top of the surface layer 130 , 230 . Normally these further particles have a larger size than the particles in the surface layer. Preferably the bottom surface 140 , 240 of the pulp mould, i.e. the surface that is now directed upwardly, is evened out, before the entire basic mould is introduced into the sintering furnace, wherein the sintering is accomplished in accordance with conventional know how. After cooling, the sintered body 100 , 200 is thereafter taken out of the basic mould and the sharp pointed objects taken out from the body, which is especially easy if these are conical. (It may be preferred to apply the “nails” to a plate, which allows for introduction and removal of the “nails” in an efficient manner). Finally the rear surface of the pulp mould 140 , 240 preferably is machined in order to obtain a totally flat supporting surface. The provision of a flat surface leads to advantages, since firstly it facilitate exact positioning of the mould half 100 , 200 onto a supporting plate 410 , secondly it provides for transmitting the applied pressure evenly through the whole mould 100 , 200 and finally it provides a very good interface for transmitting heat, e.g. from the support plate 410 . However, it is understood that there is no need to always use a totally flat surfaces, but that in many cases the substantially plane surface that is achieved directly after the sintering is sufficient.
Moreover, some parts 160 , 260 of the surface 130 , 230 ; 160 , 260 are not used to form a pulp object, but there are peripheral surfaces 160 , 260 that will not be used to form a pulp object. As a consequence, these surfaces 160 , 260 are given a permeability that is substantially smaller than the moulding surfaces 130 , 230 . As mentioned above, this may be achieved by applying a thin impermeable layer 161 , 261 having appropriate properties, e.g. any kind of paint having sufficient strength durability to maintain its impermeable function when used under operating conditions.
The pulp moulds 100 , 200 are operated by pressing the moulds 100 , 200 together so that the moulding surfaces 130 , 230 face each other. In the forming space 300 between the moulding surface 130 , 230 a wet fibrous content is arranged on one of the moulding surfaces 130 , 230 , preferably by means of suction. The pulp moulds 100 , 200 can be heated during the pressing operation and the resulting temperature at the moulding surfaces is preferably above 200° C., most preferred around 220° C. By pressing the pulp moulds 100 , 200 quick with impulse pressing under high pressure and high temperature, large parts of the water in the fibrous content vaporises and the steam quickly expands and tries to escape the narrow area. The steam can evacuate the pulp moulds 100 , 200 by means of the porosity of moulding surface 130 , 230 , the support structure 120 , 220 , the base structure 110 , 210 and the plurality of drainage channels 130 , 230 .
Means of vacuum suction can further increase the evacuation speed and increase the amount of liquid and steam leaving the fibrous content. When the pulp moulds 100 , 200 again are separated from each other, the moulded pulp object which has been created from the fibrous content, is held to one of the moulding surfaces 130 , 230 preferably by means of suction. Possibly also a gentle blow is applied through the opposite surface 230 , 130 at this moment to safeguard that the pulp object leaves with the desired mould half. When separating the pulp moulds 100 , 200 a negative pressure can occur in the forming space 300 , this negative pressure is far smaller than the pressing pressure. The conical endings of the plurality drainage channels 150 , 250 together with the small openings Ø 3 as well as the difference between the pore sizes 132 d , 232 d in the moulding surface 130 , 230 , the pore sizes 122 d , 222 d of the support layer 120 , 220 and the pore sizes 112 d , 212 d of the base structure 110 , 210 , functions as a flow resistance and restrain backflow to the forming space 300 , thereby restraining backflow to the fibrous content.
The invention is not limited by what is described above but may be varied within the scope of the appended claims.
Of course the configurations of the female 200 and male 100 moulds can differ from each other. The sintered particles 131 , 231 in the moulding surface 130 , 230 may differ in sizes, i.e. 131 d and 231 d may have different values. Likewise the sintered particles 121 , 221 in the support layer 120 , 220 may differ in sizes, i.e. 121 d and 221 d may have different values. Similarly the sintered particles 111 , 211 in the base structure 110 , 210 may differ in sizes, i.e. 111 d and 211 d may have different values. The thickness 133 , 233 of the moulding layer 130 , 230 preferably lies within 0.01 mm-1 mm and it is evident for the skilled person that the thickness 133 and the thickness 233 may differ from each other. The thicknesses of the support layer 123 , 223 may also differ from each other. It is also to be understood that in some embodiments the plurality of drainage channels 150 , 250 may be used in only one of the moulds 100 , 200 or in none of the moulds 100 , 200 . Also the spatial placement of the plurality of drainage channels 150 , 250 may differ between the moulds 100 , 200 as well as the size parameters Ø 1 , Ø 2 , Ø 3 , t 1 , t 2 and other shape characteristics of the plurality of drainage channels 150 , 250 . Obvious the distribution density of the plurality of drainage channels 150 , 250 may also differ between the female 200 and the male 100 mould. Furthermore the skilled person realises that the plurality of drainage channels 150 , 250 may differ in size and shape within an individual mould 100 , 200 . Furthermore the moulding surface 130 , 230 may comprise particles of different materials, shapes and sizes and may be divided into different segments, each segment comprising a certain particle type. Likewise the support layer 120 , 220 may comprise particles of different materials, shapes and sizes and may comprise different substantial layers, e.g. each substantial layer comprising a certain particle type. For instance the support layer 120 , 220 may comprise several layers where the size of the sintered particles 121 , 221 gradually is increased whit the smallest particles adjacent to the moulding surface 120 , 220 and the largest particles adjacent to the base structure 110 , 210 . Similar the base structure 110 , 210 may comprise particles of different materials, shapes and sizes and may be divided into different substantial layers comprising, e.g. each substantial layer comprising a certain particle type. The shape of the sintered particles of the base structure 110 , 210 , the support layer 120 , 220 and the moulding surface 130 , 230 may for example be spherical, irregular, short fibres or of other shapes. The material of the sintered particles may for example be bronze, nickel based alloys, titanium, copper based alloys, stainless steel etc. Furthermore it is to be understood that the shape of the mould 100 , 200 is decided by the wanted shape of the fibrous object and that the shape of the embodiments are by means of example. Since the pulp moulds 100 , 200 are produced using a sintering technique very complex shapes can be formed. For example a graphite form or a stainless steel form can be used for the sintering process and such a graphite form or stainless steel form can easily be manufactured in a workshop in complex shapes and with high accuracy. This makes it easy and cost effective to test alternative shapes for the fibrous object. Furthermore low production series of fibrous objects can be commercial possible due to the relative low cost of manufacturing a pulp mould 100 , 200 of the present invention. It is further to be understood that both pulp moulds 100 , 200 can be heated during operation as well as only one of the pulp moulds 100 , 200 as well as none of the pulp moulds 100 , 200 . The pulp moulds 100 , 200 can be heated in a wide variety of ways, a heated metal plate 410 can be attached to the bottom 140 , 240 of the pulp moulds 100 , 200 , hot air can be blown at the pulp mould 100 , 200 , heating elements can be added inside the base structure 110 , 210 , a gas flame can heat the pulp mould 100 , 200 , inductive heat may be applied, microwaves may be used, etc. Furthermore a vacuum source can be applied to the bottom 140 , 240 of both pulp moulds 100 , 200 , as well as to the bottom 140 , 240 of only one of the pulp moulds 100 , 200 , as well as to none of the pulp moulds 100 , 200 . Moreover the source of pressing the pulp mould 100 , 200 together can be imposed on both pulp moulds 100 , 200 or to only one of the pulp moulds 100 , 200 fixating the other pulp mould 200 , 100 . Furthermore merely one of the pulp moulds 100 , 200 could be used as a stand alone forming tool, to form a wet fibrous object in a conventional manner, i.e. normally by means of suction and thereafter normally dried in an oven, i.e. without any pressing steps. Furthermore the skilled man realises that the voids 114 , 214 , 124 , 224 can be filled with particles of appropriate sizes depending of the manufacturing technique used in creating the sintered pulp mould 100 , 200 . Moreover in some situations there might not be necessary to have an outermost layer having such small particles as the moulding surface 130 , 230 of the invention. It is to be understood that the pulp mould of the invention can be used without the moulding layer, i.e. the support layer 120 , 220 on top of the base structure 110 , 210 , as well as only the base structure 110 , 210 as the outermost layer. For instance in the forming step of the pulp moulding process, the pulp mould 100 , 200 may have larger particles in the outermost layer than in forthcoming pressing steps. Depending of an actual embodiment of the invention the drainage channels 150 , 250 could have its pointed opening Ø 3 anywhere in the interval from the border between the base structure 110 , 210 and the support layer 120 , 220 till the border between the moulding surface 130 , 230 and the forming space 300 . Moreover, using the support and heat plate 410 beneath the pulp mould 100 , 200 where the suction openings 412 are arranged to mate the bottom openings Ø 1 of the plurality of drainage channels 150 , 250 , it is obvious that it is preferred that the mating is a close match as possible and preferably every suction opening 412 always mate a corresponding bottom opening Ø 1 , but of course the invention is not limited to a perfect match rather the suction openings 412 could differ in diameters contra the bottom openings Ø 1 and the number of suction openings 412 could be larger as well as smaller than the corresponding bottom openings Ø 1 . Since the pulp mould 100 , 200 preferably are constructed by metal particles and since the pulp mould does not have a relief shape, i.e. the thickness of the pulp mould 100 , 200 is not constant following the contour of the pulp moulded object, but has preferably a flat bottom 140 resulting in that the thickness of the pulp mould 100 , 200 varies depending of the shape of the pulp moulded object, the pulp mould is able to withstand very high pressure without deforming or collapsing compared to a pulp 100 , 200 mould having a relief shape and/or comprised by a material of less strength, for instance glass beads. | This invention relates to a porous pulp mold comprising sintered particles and a plurality of drainage channels. The pulp mold of the invention can be produced in a fast and cost effective way. The molding surface of the invention comprises small pore openings, to evacuate fluid and prevent fibers from entering the pulp mold. Furthermore the pulp mold of the invention comprises drainage channels improving the drainage capabilities of the pulp mold. The molding surface can be heated to at least 200° C., due to high heat conductivity of the pulp mold and its ability to withstand high temperatures. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Patent Application No. 10 2015 203 995.1, filed Mar. 5, 2015, the contents of which are hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to an external rotor of a device for the contactless transmission or rotary movements, in particular of an electric motor. The invention, furthermore, relates to an electric motor, a generator or a magnetic coupling with such an external rotor.
BACKGROUND
[0003] External rotors for the contactless transmission of rotary movements can be designed for example as couplings, the function of which is based on the effect of a magnetic field; in drive technology, these are called magnetic field couplings. Such magnetic field couplings are employed according to the prior art in order to contactlessly transmit rotational moments across an air gap or through a wall and are therefore often employed in fluid-flow machines such as for example fluid pumps.
[0004] From EP 1 239 572 A2 a generic external rotor for the contactless transmission of rotary movements, specifically a magnetic coupling, is known, which comprises two magnetic coupling elements, which are mechanically decoupled from one another through a gap. The two magnetic coupling elements are magnets which are polarised in a segmented manner, which are each attached on the face ends facing one another.
[0005] In order to be able to achieve as high as possible an efficiency of such an external rotor it is already known to design permanent magnets of an external rotor in an annular segment form and to arrange these alternatingly in a closed ring in circumferential direction. Because of this it is possible to utilise the complete space that is available in order to place individual permanent magnet segments there. Because of this, a closed annular arch of individual permanent magnet segments can thus be formed. In certain applications it is additionally desirable that the individual permanent magnet segments of the external rotor are embedded into a pocket of the external rotor, which prevents axial shifting or detaching of the permanent magnet segments. Inserting known annular segment-shaped permanent magnet segments in such a pocket of the external rotor however is exclusively possible by axially inserting at least the “keystone”, since closed annular arches cannot be otherwise constructed from the individual permanent magnet segments. Alternatively to this, arranging the individual permanent magnet segments in the external rotor is merely possible in a form that is not completely annularly closed.
SUMMARY
[0006] The present invention deals with the problem of stating an improved or at least an alternative embodiment for an external rotor of the generic type, which is characterized in particular by a simplified production method and a high efficiency.
[0007] According to the invention, this problem is solved through the subject of the independent Claim(s). Advantageous embodiments are subject of the dependent claims.
[0008] The present invention is based on the general idea of designing individual ring segment-like permanent magnets in such a manner that these can be alternatingly arranged in a closed ring (permanent magnet segment ring), and a purely radial assembly is also made possible, that is no compulsory axial inserting of at least one “keystone” (last permanent magnet segment) has to take place. To this end, a number of different permanent magnet segments of ring segment-like design is provided, wherein at least one lateral surface of at least one such permanent magnet segment, by way of which the same is in contact with adjacent permanent magnet segments, deviates from a radial direction. Specifically this means for example that individual permanent magnet segments have lateral surfaces which conically taper towards the inside, while other permanent magnet segments have lateral surfaces which conically taper towards the outside. This makes possible a purely radial assembly of the individual permanent magnet segments to form a closed permanent magnet segment ring, wherein the last permanent magnet segment can also be inserted in radial direction, since the same comprises lateral surfaces which conically taper towards the outside and because of this can be inserted wedge-like into the permanent magnet segment ring to be closed with this last permanent magnet segment. Because of this, assembly, in particular, of such a permanent magnet segment ring in a pocket of an external rotor that is closed radially and at the face end in particular can be achieved comparatively easily, wherein because of the shaping of the individual permanent magnet segments according to the invention the annular installation space that is available can be completely occupied with permanent magnet segments, which in turn results in a high efficiency of the external rotor. Alternatively to permanent magnet segments with lateral surfaces which conically taper towards the inside and permanent magnet segments with lateral surfaces which conically taper towards the outside, at least one permanent magnet segment with lateral surfaces running in parallel can also be provided. In this case, the other permanent magnet segments usually have lateral surfaces which conically taper towards the inside, i.e. converging lateral surfaces. Obviously, multiple such permanent magnet segments with lateral surfaces running in parallel can also be provided, which are alternatingly arranged with other permanent magnet segments in the permanent magnet segment ring.
[0009] In an advantageous further development of the solution according to the invention, at least a number of first permanent magnet segments of ring segment-like design and at least a number of second permanent magnet segments of ring segment-like design are provided, which are alternating arranged in a closed permanent magnet segment ring. The first permanent magnet segments in this case comprise lateral surfaces which conically taper towards the inside, while the second permanent magnet segments have lateral surfaces which conically taper towards the outside. Because of this, first and second permanent magnet segments can be alternatingly inserted in the external rotor initially, wherein finally a second permanent magnet segment with lateral surfaces which conically taper towards the outside can thus be inserted into the permanent magnet segment ring to be closed and fixed. Such an external rotor can for example comprise three first permanent magnet segments and three second permanent magnet segments.
[0010] In an embodiment of the external rotor according to the invention that is alternative to this, a number of third permanent magnet segments of ring segment-like design and a complementary number of fourth permanent magnet segments of ring segment-like design are provided, which are alternatingly arranged in a permanent magnet segment ring. The third and the fourth permanent magnet segments in this case have lateral surfaces which conically taper towards the inside. Additionally, a number of fifth permanent magnet segments of ring segment-like design is now provided, which comprise lateral surfaces which conically taper towards the outside and in each case are arranged between a third and a fourth permanent magnet segment. In this case, the ultimately closed permanent magnet segment ring thus consists of third, fourth and fifth permanent magnet segments, wherein the third and the fourth permanent magnet segments are preferentially designed in the same shape and merely have an inverted polarity. Practically, the fifth permanent magnet segments are designed as transverse magnets and because of this do not generate magnetic field lines running in radial direction, but magnet field lines which substantially run in circumferential direction between two adjacent permanent magnet segments. A radial assembly of the individual permanent magnet segments to form a closed permanent magnet segment ring is also comparatively easy with such third, fourth and fifth permanent magnet segments, provided that as “keystone” a fifth permanent magnet segment with lateral surfaces which conically taper radially to the outside is used. This fifth permanent magnet segment can then be inserted wedge-like in radial direction towards the outside as “keystone” between a third and a fourth permanent magnet segment element. Fixing the individual permanent magnet segments in the external rotor in this case can be effected for example by means of gluing.
[0011] In a further alternative embodiment of the external rotor according to the invention, a number of six permanent magnet segments of ring segment-like design and a number of seventh permanent magnet segments of ring segment-like design that is complementary to the former is provided, which in turn are alternatingly arranged in a permanent magnet segment ring. The sixth and seventh permanent magnet segments in this case have lateral surfaces which conically taper towards the outside, wherein additionally a number of eighth permanent magnet segments of ring segment-like design is provided, which have lateral surfaces which conically taper towards the inside and in each case are arranged between a sixth and a seventh permanent magnet segment. Here, three sixth, three seventh as well as eight permanent magnets can form a closed permanent magnet segment ring. Here, the eight permanent magnet segments can likewise in turn be designed as transverse magnets. Such an embodiment of the individual permanent magnet segments also makes possible a comparatively simple radial assembly to form a closed permanent magnet segment ring, without the last permanent magnet segment having to be inserted axially.
[0012] Here it is clear that each permanent magnet segment comprises a pole pair with at least one north pole and one south pole. When using so-called transverse magnets, a Halbach magnetization is also possible.
[0013] Further important features and advantages of the invention are obtained from the subclaims, from the drawings and from the associated figure description with the help of the drawings.
[0014] It is to be understood that the features mentioned above and still to be explained in the following cannot only be used in the respective combination stated but also in other combinations or by themselves without leaving the scope of the present invention.
[0015] Preferred exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein same reference characters relate to same or similar or functionally same components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The drawings show, in each case schematically,
[0017] FIG. 1 a longitudinal sectional representation through an external rotor according to the invention with permanent magnet segments arranged therein,
[0018] FIG. 2 a cross-sectional representation through the external rotor according to the invention with a first embodiment,
[0019] FIG. 3 a representation as in FIG. 2 , however with a second embodiment,
[0020] FIG. 4 a representation as in FIG. 3 , however with modified embodiment,
[0021] FIG. 5 a cross-sectional representation through the external rotor according to the invention with multiple permanent magnet segments designed as transverse magnets with parallel lateral surfaces,
[0022] FIG. 6 a cross-sectional representation through the external rotor according to the invention with a permanent magnet segment with parallel lateral surfaces,
[0023] FIG. 7 a cross-sectional representation through the external rotor according to the invention with multiple permanent magnet segments with parallel surfaces.
DETAILED DESCRIPTION
[0024] According to FIG. 1 , an external rotor 1 according to the invention, which for example can be arranged in an electric motor 2 , a generator 3 , a magnetic transmission 21 or a magnetic coupling 4 comprises a number of permanent magnet segments 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 19 of different ring segment-like design, which are alternatingly arranged in a closed permanent magnet segment ring 18 (see also FIGS. 2 to 4 ). At least one lateral surface 12 , 13 of at least one permanent magnet segment 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 19 by way of which the same is in contact with an adjacent permanent magnet segment 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 19 , deviates from a radial direction 15 in this case. This means that the planes of the lateral surfaces 13 , 14 intersect outside the rotor 1 or within the same, however not in the centre 16 or with parallel lateral surfaces 13 , 14 not at all.
[0025] Now considering the first alternative embodiment, which is shown in FIG. 2 , it is evident that the external rotor 1 according to the invention comprises at least a number of first permanent magnet segments 5 of segment-like design and at least a complementary number of second permanent magnet segments 6 or ring segment-like design, which according to the right representation in FIG. 2 are alternatingly arranged in the installed state in a closed permanent magnet segment ring 18 . The first permanent magnet segments 5 in this case comprise lateral surfaces 13 , 14 which conically taper towards the inside, whereas the second permanent magnet segments 6 have lateral surfaces 13 , 14 which conically taper towards the outside. For constructing the permanent magnet segment ring, the first permanent magnet segments 5 are thus initially introduced into the external rotor 1 or a pocket 17 arranged there, in order to subsequently insert the second permanent magnet segments 6 of wedge-like design in the sections that remain vacant. As is already clearly visible from FIGS. 1 and 2 , a radial assembly of the permanent magnet segment ring 18 is possible in this case, which would not be possible with ring segment-like permanent magnet segments of purely identical design, which would be arranged in the manner of a closed arch ring.
[0026] According to FIG. 2 , three first permanent magnet segments 5 and three second permanent magnet segments 6 are provided in this case.
[0027] Looking at the alternative embodiment of the external rotor 1 shown according to FIG. 3 , a number of third permanent magnet segments 7 of ring segment-like design and a complementary number of fourth permanent magnet segments 8 of ring segment-like design is noticeable, which according to the right representation in FIG. 3 in turn are alternatingly arranged in a permanent magnet segment ring 18 in circumferential direction. Additionally, a number of fifth permanent magnet segments 9 of ring segment-like design is provided, which has lateral surfaces 13 , 14 which conically taper towards the outside, and which in each case are arranged between a third and a fourth permanent magnet segment 7 , 8 . The third and fourth permanent magnet segments 7 , 8 by contrast have lateral surfaces 13 , 14 which conically taper towards the inside and are additionally designed identical in shape. The fifth permanent magnet segments 9 in this case are designed as transverse magnets and thus do not generate any radial magnetic field lines, but magnetic field lines running in circumferential direction between two adjacent third and fourth permanent magnet segments 7 , 8 . Because of this, a so-called Halbach magnetization can be achieved in particular. Altogether, three third and three fourth permanent magnet segments 7 , 8 each and a total of six fifth permanent magnet segments 9 are provided in total in the external rotor 1 shown according to FIG. 3 .
[0028] FIG. 4 shows a further possible alternative embodiment of the external rotor 1 according to the invention, with which a number of sixth permanent magnet segments 10 designed of ring segment-like design and a complementary number of seventh permanent magnet segments 11 of ring segment-like design is provided, which in turn are alternatingly arranged in a permanent magnet segment ring 18 . Alternatingly, in this case, does not necessarily mean that the sixth and seventh permanent magnet segments 10 , 11 have to directly abut one another, but as shown in the present case subject to the intermediate connection of an eight permanent magnet segment 12 of ring segment-like design. The sixth and seventh permanent magnet segments 10 , 11 in this case have lateral surfaces 13 , 14 which conically taper towards the outside, while the eight permanent magnets 12 of ring segment-like design—as already mentioned, have lateral surfaces 13 , 14 which conically taper towards the inside and in this case are likewise designed as transverse magnets.
[0029] The sixth and seventh permanent magnet segments 10 , 11 in this case are designed identical in shape, wherein altogether three sixth and three seventh permanent magnet segments 10 , 11 as well as six eight permanent magnet segments 12 are provided.
[0030] Looking at the external rotors 1 shown in the FIGS. 5 to 7 , an embodiment that is alternative to the previous figures is evident, in the case of which at least one permanent magnet segment 19 with lateral surfaces 13 , 14 running in parallel can be provided. In this case, the other permanent magnet segments, which for example are designed similar to the first permanent magnet segments 5 or the third permanent magnet segments 7 , have lateral surfaces 13 , 14 which conically taper towards the inside, i.e. converge. Obviously, multiple such permanent magnet segments 19 with lateral surfaces 13 , 14 running in parallel can also be provided, which are arranged in the permanent magnet segment ring 18 alternating with other permanent magnet segments.
[0031] In the case of the external rotor 1 according to FIG. 5 , the permanent magnet segments 19 are designed as transverse magnets and because of this form a so-called Halbach magnetization. The permanent magnet segments which are alternatingly arranged between the permanent magnet segments 19 are inversely poled here.
[0032] In FIG. 6 , only a single permanent magnet segment 19 is equipped with parallel lateral surfaces 13 , 14 , wherein altogether six permanent magnet segments each with alternating polarity are provided. According to the embodiment according to FIG. 6 , permanent magnet segments 20 , the lateral surfaces 13 , 14 of which run in lateral direction 15 and intersect in the centre 16 are also possible.
[0033] In FIG. 7 , a total of three permanent magnet segments 19 are equipped with parallel lateral surfaces 13 , 14 and arranged between three other permanent magnet segments. The permanent magnet segments 19 as well as the three other permanent magnet segments are each designed identical in shape here.
[0034] All show embodiments of the external rotor 1 according to the invention have in common that an assembly of the individual permanent magnet segments 5 to 12 and 19 is possible in radial direction, which is of great advantage in particular when the external rotor 1 , as shown in FIG. 1 , comprises a pocket 17 and because of this engages about the permanent magnet segments 5 to 12 and 19 both on an outside and also on both face ends.
[0035] Obviously it is entirely immaterial if the permanent magnet segments 5 to 12 and 19 are magnetised radially, diametrically or any other way provided these are arranged accordingly in the permanent magnet segment ring 18 . However, it is obviously also conceivable here that the individual permanent magnet segments 5 to 12 , 19 are magnetised even prior to the installation in the external rotor 1 , or are magnetised thereafter. | An external rotor of a device for contactless transmission of rotary movements, for example of an electric motor, a magnetic transmission, a generator or a magnetic coupling, may include a plurality of different permanent magnet segments configured ring segment-like that are alternatingly arranged in a closed permanent magnet segment ring. At least one lateral surface of at least one permanent magnet segment of the plurality of permanent magnet segments may deviate from a radial direction. The at least one permanent magnet segment via the at least one lateral surface may be in contact with another permanent magnet segment of the plurality of permanent magnet segments. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 09/570,880, filed May 15, 2000, which is a continuation of U.S. patent application Ser. No. 08/801,560, filed Feb. 18, 1997, now U.S. Pat. No. 6,070,660, issued on Jun. 6, 2000.
FIELD OF THE INVENTION
The present invention pertains to a control system for continuously varying the speed of a fan drive motor for a forced air indoor space heating/cooling system during startup and after shutdown of a heating/cooling cycle.
BACKGROUND OF THE INVENTION
Conventional controls for forced air heating and cooling systems often provide for delayed startup of the fan drive motor at a single operating speed and delayed shutdown of the drive motor from a single operating speed after shutdown of the heat exchangers of the heating/cooling system. Conventional controls are designed to minimize unpleasant cold or hot drafts of air and to capture residual heat/cooling effect. However, changing motor speed abruptly from a deenergized or shutoff state to full speed usually generates unpleasant noise, does not preclude stratification of air in the system ductwork or in the space being heated or cooled, nor does such operation maximize the capture of residual heat/cooling effect of the system heat exchange equipment.
Control systems have been developed for forced air heating/cooling systems wherein the indoor space air circulating fan drive motor is driven at reduced speed for a period of time during startup and at a reduced speed for a period of time during the run-on or shutdown phase of the heating/cooling system operating cycle. Again, this type of control system does not minimize the stratification of warm or cold air in the ductwork or the space being heated or cooled nor does such a system maximize the capture of residual heating/cooling effect.
Prior U.S. patent applications Ser. Nos. 09/570,880 and 08/801,560 (now U.S. Pat. No. 6,070,660) assigned to the assignee of the present invention and referenced hereinabove are directed to an improved fan or blower drive motor control system and method for forced air heating/cooling systems wherein the fan drive motor speed is continuously varied during a starting phase and a shutdown phase of operation of the heating/cooling system. In one embodiment of the control system disclosed in the aforementioned patent application and patent, the system senses temperature in the airflow circuit of the heating/cooling system and prevents premature or unwanted operation of the fan drive motor. The present invention is directed to improvements in control systems of that general type. The subject matter of U.S. Pat. No. 6,070,660 issued Jun. 6, 2000 to Howard P. Byrnes, et al. is incorporated herein by reference, in its entirety.
SUMMARY OF THE INVENTION
The present invention provides an improved fan or blower drive motor control system for a forced air heating/cooling system wherein a control circuit is provided which substantially continuously varies the speed of the fan drive motor during a starting phase and a shutdown phase of operation. The control system may be easily adapted to conventional heating/cooling system controls to vary the forced air fan or blower drive motor speed in response to temperatures sensed in the heating/cooling system airflow circuit. The control system is particularly adapted for but not limited to use with permanent split capacitor or shaded pole blower or fan drive motors.
The control circuit includes an onboard power supply, an ac voltage wave crossover detector circuit and a control circuit for firing a triac to control the drive motor speed. The control system also includes a minimum speed detector circuit and a circuit which provides for continued operation of the fan drive motor at the minimum speed, if desired, or motor shutoff after reaching the minimum speed.
The control system of the present invention includes one embodiment which comprises a temperature sensor disposed in an airflow ductwork on the so-called return air side of the heating and/or cooling equipment and a temperature sensor on the downstream or so-called supply air side of the heating and/or cooling equipment.
In another embodiment, three sensors are disposed in the ductwork including the return air sensor which is disposed upstream with regard to the direction of airflow from an air heater heat exchanger, a heat sensing sensor which is disposed downstream of the air heater heat exchanger and a third sensor which is disposed downstream of an air cooling heat exchanger, such as an evaporator coil, for example. In this way a more versatile control system is provided and more accurate sensing of temperature is obtained, depending on the operating condition of the system, heating versus cooling.
The control systems of the present invention advantageously reduce energy consumption of conventional forced air heating and cooling systems, improve recovery of residual heating/cooling effect in conventional forced air heating/cooling systems, minimize stratification of air in the airflow circuit and the space being heated or cooled and reduce cold or hot air drafts during operation of the heating/cooling system. Moreover, by substantially continuously varying the fan or blower drive motor speed during startup and shutdown, noise associated with fan or blower operation is reduced and the circulation of air at a temperature other than normally sensed or preferred by occupants of an indoor space being heated or cooled is also reduced.
Those skilled in the art will further appreciate the important features and advantages of the invention, together with other superior aspects thereof upon reading the detailed description which follows in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of air temperature versus flow and motor speed indicating the change in airflow with increasing temperature sensed in the airflow circuit as well as decreasing flow with decreasing temperature in the airflow circuit in accordance with the control system of the present invention;
FIG. 2 is a schematic diagram of one preferred embodiment of a control system in accordance with the invention; and
FIG. 3 is a schematic diagram of another preferred embodiment of the invention and comprises FIGS. 3A, 3 B and 3 C, which may be viewed when arranged in accordance with the map diagram of FIG. 3; and
FIG. 4 is a somewhat schematic illustration of an air conditioning system showing one preferred arrangement of the locations of the sensors for the control system of FIG. 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. Conventional elements are shown in somewhat generalized or schematic form in the interest of clarity and conciseness.
Referring to FIG. 1, the diagram illustrates a preferred change in motor speed and airflow rate through a conventional forced air heating/cooling system when the system thermostat senses the need for heating, for example, at a temperature setpoint of 78° F. in the space being heated. When the temperature sensed by the conventional system temperature sensor or thermostat drops below the setpoint of 78° F., for example, the furnace or heater turns on and the control system of the invention energizes the blower or fan drive motor at a minimum speed. When the air temperature sensed in the system ductwork increases, primarily at a location just downstream of the heater heat exchanger, as compared with the temperature in the return air duct upstream of the heater heat exchanger, the motor speed is increased.
Motor speed is proportional to airflow increase, and generally follows curve 10 in FIG. 1 until the temperature sensed by the sensor which is downstream of the heater heat exchanger reaches a setpoint of 110° F. At this time the blower motor continues to operate at full speed until the thermostat in the space being heated indicates that the demand for heating has been satisfied and the heater or “burner” is turned off so that the heater heat exchanger begins to cool. Accordingly, as the temperature sensed by the sensor which is disposed downstream in the direction of flow of air through the system decreases in relation to the return air temperature sensed at a point upstream of the heat exchanger, the control system of the invention varies the fan speed by continuously decreasing the fan drive motor speed. Airflow provided by the motor driven fan decreases along curve 12 in FIG. 1 until a minimum speed of the motor is reached which may result in continuous operation at the minimum speed or, at a slightly lower temperature, motor shutoff occurs.
Accordingly, motor operation and the airflow characteristic, as a function of the sensed temperature, provides for delivery of residual heat from the heater heat exchanger to the space being heated with increased efficiency, airflow increases and decreases gradually on start and stop of the heater or burner for quiet operation of the system and stratified air layers at various temperatures are substantially eliminated in the heating/cooling system ductwork and in the space being heated or cooled. More efficient operation of the heating/cooling system is obtained and a greater comfort level is provided for persons occupying the space controlled by a system in accordance with the invention.
Referring now to FIG. 2, there is illustrated a schematic diagram of one preferred embodiment of a temperature sensing, variable speed fan or blower motor control system in accordance with the invention and generally designated by the numeral 20 . The control system 20 is operable to sense the temperature in a ductwork of a conventional forced air heating and cooling system, a section of which ductwork is illustrated in FIG. 2 and generally designated by the numeral 22 . Ductwork 22 includes a return air duct part 24 whereby airflow from a space being heated or cooled is being returned for heating by a heater heat exchanger 26 or cooled by a cooling heat exchanger 28 . Accordingly, a return air temperature sensor R 11 is disposed in the ductwork 22 upstream of the heat exchanger for the heater 26 and a so-called supply air sensor R 9 is disposed in ductwork 22 downstream, with respect to the direction of airflow, of the air cooling heat exchanger 28 whereby supply air treated by the heating/cooling system is then returned to the control space via a supply air duct 30 . In fact, the ductwork 22 may comprise a conventional forced air furnace/air conditioning system wherein the heat exchanger 26 includes a gas fired burner or electrical resistance heater, not shown, and the heat exchanger 28 is an evaporator coil of a conventional vapor compression refrigeration circuit, not shown. The illustration of FIG. 2 with respect to the heating/cooling system is exemplary.
Referring further to FIG. 2, a HEAT/COOL SELECT circuit is indicated whereby, for example, when a heater associated with heat exchanger 26 is energized, such as by opening a gas burner valve, for example, 24 volt AC electrical power is applied across terminals P 5 and P 6 . Alternatively, when an air cooling system is operable, such as a vapor compression refrigeration system, and the compressor thereof is energized, 24 volt AC power is applied across terminals P 4 and P 6 . Power for the control system 20 is supplied by a 120 volt AC source at terminal P 2 and a neutral conductor P 2 ′. Alternatively, 24 volt AC power may be applied at terminals P 7 and P 2 ′. A fan or blower drive motor 32 may be connected at terminals P 2 ′ and P 2 ″ as indicated in FIG. 2 . The motor 32 may be of a type described in U.S. Pat. No. 6,070,660 which is incorporated herein by reference. The control system 20 is preferably connected to the motor medium speed winding as in the system of the ' 660 patent.
As further shown in FIG. 2, a 12 volt DC power supply circuit is made up of capacitors C 2 and C 10 , resistor R 15 , a diode D 2 and a Zener diode D 5 . A four diode bridge BR 1 takes either the 24 volt AC signal from a step down transformer, not shown, or the 120 volt AC source at terminals P 2 and P 2 ′. A RESET circuit comprising resistors R 21 , R 24 , R 25 , R 26 , R 27 , R 44 , diodes D 4 and D 6 , capacitor C 4 and amplifier U 2 :A is operable to receive full wave voltage from the diode bridge BR 1 through resistors R 25 , R 26 , diode D 6 and amplifier U 2 :A to capacitor C 6 for the purpose of discharging capacitor C 6 every half cycle. Thus an output pulse always starts at the proper moment on each half cycle. If 24 volt AC power is input to the power supply and RESET circuits, jumper JP 2 is open and is shorted if there is no 24 volt AC supply.
Sensors R 9 and R 11 are preferably thermistors which are substantially similar and interposed in a HEAT/COOL RAMP GEN circuit to generate signals as the temperature differences change between each sensor location. If both sensors are at the same temperature the output of the sensors will be one-half of the 12 volt DC supply voltage. If the downstream or so called supply air sensor R 9 senses a temperature greater than the return air sensor R 11 , the output voltage at conductor 34 increases. If the temperature sensed by sensor R 9 is less than that sensed by sensor R 11 , voltage at conductor 34 will decrease. The output signal from the sensors R 9 and R 11 is input to the ramp circuits indicated in FIG. 2 as the COOL RAMP and the HEAT RAMP. If the output signal voltage is increasing the HEAT RAMP circuit is activated which comprises resistors R 10 , R 12 , R 13 , R 14 , R 16 , R 17 , R 18 and R 20 , capacitors C 8 and C 13 , diode D 3 , buffer amplifier U 1 :C and amplifier U 1 :A arranged in circuit as shown in FIG. 2 . The output signal of the HEAT RAMP circuit is imposed on conductor 36 .
The COOL RAMP circuit is also connected to conductor 34 to receive the resultant output signal from sensors R 9 and R 11 and if the signal magnitude is decreasing, a voltage output at conductor 36 , 37 is increasing. The ramp output voltage generated by the COOL RAMP circuit is provided by circuit components including resistors R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , capacitor C 14 , diode D 1 and amplifiers U 1 :B and U 1 :D. Capacitors C 13 and C 14 slow the change in the output signal of amplifier U 1 :B or U 1 :C which will minimize the chance of lockup of motor 32 . Capacitors C 13 and C 14 also minimize unwanted electrical noise from entering the ramp circuits previously described.
The control system 20 further includes a pulse generator or PULSE GEN circuit including resistors R 35 , R 36 , R 37 , capacitors C 5 , C 6 and C 9 , opto-isolator U 3 and diode D 10 . Ramp output voltage is input through resistors R 19 and R 28 to the PULSE GEN circuit and operational amplifier U 2 :B which has a reference voltage set at its negative input. When the ramp voltage exceeds this reference voltage, the output of amplifier U 2 :B goes “high”. Capacitor C 6 connects to the ramp voltage signal on conductor 36 also. Accordingly, a sawtooth waveform is input at the positive (+) terminal of amplifier U 2 :B. Therefore, the output of the PULSE GEN circuit is a square wave whose width varies as the ramp voltage signal varies. Since the RESET circuit discharges capacitor C 6 every half cycle, the output pulse of the PULSE GEN circuit always starts at the correct time on each half cycle.
A POWER OUTPUT circuit is shown in FIG. 2 comprising resistors R 30 , R 32 , power triac Q 1 and capacitor C 7 . A square wave output signal from the PULSE GEN circuit is imposed on capacitor C 5 which causes a voltage pulse to turn on the input diode of opto-isolator U 3 and when the diode in opto-isolator U 3 conducts its output triac turns “on”. This action causes current to flow into the gate of the power triac Q 1 which is connected to motor 32 . When current flows through the power triac Q 1 , motor 32 is energized to rotate to drive fan or blower 33 which is operably associated with the ductwork 22 . A snubber comprising resistor R 32 and capacitor C 7 are connected to power triac Q 1 to protect triac Q 1 from unexpected line voltage surges.
Referring still further to FIG. 2, a CUTOFF circuit includes resistors R 33 , R 34 , R 38 , R 39 and R 40 , diode D 8 and amplifier U 2 :C. Amplifier U 2 :C is operable to receive a variable voltage signal at its negative terminal via conductor 37 and, when the ramp voltage drops to a predetermined value, amplifier U 2 :C goes “high” and provides a signal coupled through diode D 8 to the PULSE GEN circuit. When a “high” signal is imposed on the negative (−) terminal of amplifier U 2 :B, the output signal of U 2 :B goes “low” shutting off an output signal from power triac Q 1 and motor 32 stops. Accordingly, when the ramp voltage at conductors 36 , 37 increases slightly above a dropout value, the CUTOFF circuit output at amplifier U 2 :C goes low. This allows the ramp voltage to resume normal output to control the motor 32 through the triac Q 1 .
The CUTOFF circuit, including amplifier U 2 :C, is operably connected to a jumper JP 1 in a MIN SPEED circuit as shown in FIG. 2 . The discussion hereinabove regarding the CUTOFF circuit assumes that the jumper JP 1 is open. When jumper JP 1 is closed, control system supply voltage is coupled through diode D 11 to the negative input terminal of amplifier U 2 :C. The output signal of amplifier U 2 :C is then forced “low” regardless of the ramp voltage input to amplifier U 2 :C and therefore the pulse generator is not shutoff due to the CUTOFF circuit. The MIN SPEED circuit of the control system 20 includes resistors R 19 , R 22 , R 23 , R 28 , R 46 , diodes D 9 and D 11 and amplifier U 2 :D. When the jumper JP 1 is open, the output of the MIN SPEED circuit is low at the output of amplifier U 2 :D and the adjustable resistor R 22 , which is operable to adjust the minimum speed of the motor 32 , is inoperable. When JP 1 is closed, the CUTOFF circuit previously described is disabled through diodes D 11 and resistor R 46 and the MIN SPEED circuit is enabled. Adjustment of the minimum speed resistor or potentiometer R 22 enables the motor 32 to be set to run from approximately 180 rpm to 620 rpm, for example. The motor minimum speed will hold even though there may be a zero difference between supply air and return air temperatures as sensed by the sensors R 9 and R 11 .
The aforementioned HEAT/COOL SELECT circuit includes a cooling condition input circuit including resistors R 31 and R 45 , diodes D 7 and D 14 and capacitor C 11 . A 24 volt AC signal on the aforedescribed circuit will deactivate motor 32 by deactivation of triac Q 1 . This signal overrides any signals produced by the sensors R 9 and R 11 . Consequently, when the control system 20 is connected to the medium speed winding of a motor, such as the motor 32 , and the conventional control system for the motor applies power to the high speed winding and the 24 VAC COOL signal is provided at terminals P 4 and P 6 only the desired motor winding will be energized. However, when the thermostat is satisfied in the space being cooled and a signal is removed from terminals P 4 and P 6 the control system 20 will be operable to energize the motor 32 at the medium speed winding and gradually reduce the motor speed as the temperature difference between the sensors R 9 and R 11 decreases.
Conversely, when a 24V AC HEAT input signal is provided at the HEAT/COOL SELECT circuit, the COOL RAMP circuit is disabled and only the temperature of sensor R 9 rising above the temperature of sensor R 11 will affect motor speed. The sensor R 9 temperature, when below the sensor R 11 temperature, will maintain the HEAT/COOL RAMP GEN circuit at its minimum voltage. Motor 32 will either then be at zero speed or a minimum speed depending on the selection of the connection of jumper JP 1 for cutoff or minimum speed. The heat input side of the HEAT/COOL SELECT circuit includes capacitor C 12 , diodes D 12 , D 13 and resistors R 41 and R 42 .
Lastly, the control system 20 includes a SENSOR PROTECTION circuit including resistors R 47 , R 48 , R 49 , R 50 , R 51 , capacitors C 1 , diode D 15 and amplifier U 4 :A. A positive input signal to amplifier U 4 :A of the SENSOR PROTECTION circuit is provided by the ramp output voltage signal and the protection circuit negative input to amplifier U 4 :A is connected to a reference voltage available from resistors R 49 and R 50 . When the ramp output voltage exceeds the reference voltage, the output signal of amplifier U 4 :A goes high and this DC voltage signal is connected to the opto-isolator U 3 through diode D 15 . This action causes the triac Q 1 to be on full at all times and avoid the possibility of motor lockup.
Still further, there are three ways for the ramp output voltage signal to exceed the reference voltage signal at amplifier U 4 :A, which reference is established by resistors R 49 and R 50 , namely (1) if either of the sensors R 9 or R 11 are open, (2) if both of sensors R 9 and R 11 are open or are shorted, or (3) if the design parameter for the temperature difference between sensors R 9 and R 11 has been exceeded. If any of the above noted conditions occurs the motor 32 will be fully on until the condition goes back to the system normal mode of operation or power is removed from the control system 20 .
An alternate embodiment of a control system in accordance with the invention will now be described in conjunction with FIGS. 3 and 4. In certain air conditioning systems it may be necessary to monitor a change in cooling air temperature and heating air temperature at different locations in the air conditioning system and the reference or return air sensor may be required to be mounted in a return air duct to monitor temperature in a third location. A major advantage of having the flexibility of being able to choose the location of the temperature sensors is with regard to certain installations wherein, for example, during a cooling phase of operation air is routed through a different duct than for the routing of air during heating operation. Still further, in other applications the heating/cooling equipment may be arranged such that the location of the so-called supply air sensor may be suitable for the heating mode of operation but not the cooling mode or vice versa.
By way of example, and referring to FIG. 4, there is illustrated a vertical or updraft air conditioning system 110 which includes duct or cabinet 111 . Cabinet 111 is mounted on a return air plenum 112 whereby air being returned from an air conditioned space enters the system 110 and flows upward over surfaces of a heat exchanger 114 and then further upward through an evaporator coil or air cooling heat exchanger 116 before being discharged into a supply air plenum 118 for distribution through suitable supply air ducts 120 , 122 and 124 , for example. The motor and blower or fan 32 , 33 for the system 110 is shown in one preferred location in plenum 112 in the somewhat schematic illustration of FIG. 4, but may also be located, alternatively, in the cabinet 111 , for example.
A control system 200 is illustrated in FIGS. 3A, 3 B and 3 C which is advantageous for use with the air conditioning system 110 of FIG. 4 . The system 110 of FIG. 4 is provided to illustrate that a typical location of a return air sensor 130 would be in the return air duct or plenum 112 . A heated air sensor 132 should be disposed just downstream in the direction of airflow through the system 110 of the heat exchanger 114 for sensing the temperature of heated air, and a third or cooling air sensor 134 is shown located just downstream, in the direction of airflow, from the evaporator or cooling coil 116 . With this arrangement more accurate and timely readings of the heated air temperature and the cooled air temperature is provided even though the flowpath for the air during the heating mode or the cooling mode is not through separate ducts in the exemplary system 110 .
Referring now to FIG. 3C, the control system 200 includes a POWER SUPPLY circuit substantially like the power supply for the control system 20 . Power at 120 volts AC may be applied at terminals Pi and P 3 or alternatively 24 volt AC power may be applied at terminals P 1 and P 2 . As indicated in FIG. 3C, a jumper JP 2 is applied if 120 volt AC power is connected to the control system. Motor 32 is connected between terminals P 1 and P 4 also, as indicated. The POWER SUPPLY circuit is made up of capacitors C 60 and C 50 , resistor R 200 , diodes D 50 and D 80 and bridge circuit BR 1 . Bridge circuit BR 1 is a set of four diodes which cause a fullwave bridge output signal to be developed. Since the voltage developed falls to near zero every half cycle, the output is used to synchronize a pulse generator by resetting capacitor C 140 every half cycle. A RESET circuit including diode D 70 , resistors R 280 , R 420 , R 350 , capacitor C 100 , resistor R 460 , resistor R 410 , resistor R 400 , amplifier U 2 :A 1 and diode D 110 provides an output pulse to amplifier U 2 :B 1 at the correct moment on each cycle.
Control system 200 also includes a PULSE GEN circuit, as shown in FIG. 3C, comprising resistors R 510 , R 600 and R 610 , diode D 150 , amplifier U 2 :B 1 , and capacitors C 130 , C 140 and C 110 . A voltage signal from the ramp circuits shown in FIG. 3 A and to be described further herein is provided via reference terminal 212 in FIG. 3A to reference terminal 214 in FIG. 3 C. This voltage is applied to the positive terminal of amplifier U 2 :B 1 and a reference voltage provided through resistors R 510 and R 600 is applied to the negative terminal of amplifier U 2 :B 1 . When the ramp voltage at reference terminal 214 exceeds the reference voltage, amplifier U 2 :B 1 provides a “high” output signal. Capacitor C 140 connects to the ramp voltage signal imposed on reference terminal 214 and a sawtooth waveform results at the positive terminal of U 2 :B 1 . Accordingly, the output signal of amplifier U 2 :B 1 is a square wave whose width varies as the ramp voltage imposed on reference terminal 214 varies.
A POWER OUTPUT circuit of the control system 200 includes resistors R 490 , R 570 , amplifier or opto-isolator U 60 and power triac Q 1 as well as capacitor C 120 . The aforementioned squarewave output signal from the amplifier U 2 :B 1 is connected to capacitor C 110 . A voltage pulse is formed by capacitor C 110 and diode D 150 to the input diode of opto-isolator U 60 . When the aforementioned input diode of opto-isolator U 60 conducts, an output triac of the opto-isolator U 60 turns “on” which causes current to flow into the gate of power triac Q 1 . Motor 32 is connected to the power triac Q 1 at terminal P 4 and when current flows through the triac, the motor is energized to drive fan or blower 33 . A snubber resistor-capacitor combination comprising resistor R 570 and capacitor C 120 are connected to the power triac Q 1 to protect the triac from unexpected line voltage surges.
Referring now to FIG. 3B also, a fan motor speed CUTOFF circuit is shown including resistors R 400 , R 150 , R 160 , R 180 , R 90 , R 120 , diode D 300 , diode D 200 and amplifier U 2 :C 1 . The negative terminal of amplifier U 2 :C 1 is connected to a HEAT/COOL RAMP circuit shown in FIG. 3 A through resistor R 400 via conductor 221 . When the COOL RAMP circuit output voltage drops to a predetermined level, as determined by the reference voltage at the positive terminal of amplifier U 2 :C 1 , this amplifier provides an output signal to diode D 200 and the PULSE GEN circuit by way of conductor 223 which is coupled to the negative input terminal of amplifier U 2 :B 1 . When a “high” output signal is applied via conductor 223 to amplifier U 2 :B 1 , the output signal of amplifier U 2 :B 1 goes “low” shutting down the output signal of opto-isolator U 60 and power triac Q 1 thereby deenergizing motor 32 . When the HEAT/COOL RAMP voltage signal from conductor 221 increases slightly above a so-called dropout voltage, the output signal from amplifier U 2 :C 1 goes low and allows the ramp voltage signal to resume normal action to control the motor speed through the power triac Q 1 . It should be noted that the CUTOFF circuit just described has a hysteresis equivalent to approximately 10 rpm on motor 32 .
The above description with respect to the CUTOFF circuit assumes that the jumper JP 3 , FIG. 3A, is in an open condition. When jumper JP 3 is closed, the supply voltage provided thereby enables a reference voltage to the noninverting input of amplifier U 2 :D 1 , the output voltage of which is coupled through diode D 140 to the output conductors of the HEAT/COOL RAMP and HEAT RAMP circuits and the reference terminals 212 , 214 , which determines the motor speed by biasing amplifier U 2 :B 1 as previously described. By adjusting an adjustable resistor R 540 of a MIN SPEED circuit, FIG. 3A, the minimum speed of the motor 32 can be preset.
However, when jumper JP 3 is open, switch U 5 :A 1 is connected across the JP 3 contacts. Switch U 5 :A 1 is energized through resistor R 450 which connects to a 24 volt AC HEAT signal of the HEAT/COOL SELECT circuit, FIG. 3A, by way of reference terminals 225 and 227 and by way of diode D 170 , resistor R 690 , diode D 190 , capacitor C 150 and resistor R 450 . With this arrangement, when a 24 volt AC HEAT signal is present, the MIN SPEED circuit is energized and if the MIN SPEED circuit is energized, the CUTOFF circuit, FIG. 3B, is deenergized by way of resistors R 580 and R 400 . Accordingly, when a signal is applied to the 24 volt AC HEAT input, switch U 5 :A 1 is immediately switched on and this action shorts jumper JP 3 from resistor R 530 to positive 12 volts DC. A bias voltage is applied to positive pin of amplifier U 2 :D 1 and the output of amplifier U 2 :D 1 is applied at the reference terminal 212 through diode D 140 . Therefore, as the control system 200 is operated in conjunction with the air conditioning system 110 , wherein a signal indicating a heat mode of operation is applied, the motor 32 runs at a minimum speed to provide better air circulation surrounding sensors 130 , 132 and 134 .
Adjustment of the minimum speed MIN ADJUST resistor R 540 enables the motor speed to be set from approximately 180 rpm to 620 rpm. The minimum speed of the motor 32 will hold at its designated RPM even though there may be no difference between supply air and return air temperatures.
Referring further to FIG. 3A, the HEAT/COOL SELECT circuit is operable to provide a 24 volt AC input signal at 24 VAC COOL across terminals P 6 and P 7 a and imposed on diode D 200 , resistors R 700 , R 710 , diode D 210 and capacitor C 160 . When 24 volt AC power is applied across terminals P 6 and P 7 a , motor 32 is turned off by deactivation of power triac Q 1 due to the application of an output signal at reference terminal 229 which is connected to reference terminal 231 , FIG. 3 C. In other words, when a voltage is applied to reference terminals 229 , 231 and the negative terminal of amplifier U 2 :B 1 the output signal of amplifier U 2 :B 1 goes “low” and causes opto-isolator U 60 and power triac Q 1 to shut off power to motor 32 . A signal as described above applied at reference terminal 229 overrides signals provided by return air sensor 130 and supply air sensors 132 and 134 . Accordingly, the control system 200 is also operable to avoid supplying power to both the high speed winding and the medium speed winding of the motor 32 when the thermostat for the air conditioning system 110 has called for operation in the cooling mode and the motor is being separately controlled by the conventional motor control system to operate at a high speed. However, as with the control system 200 when a control signal is removed across terminals P 6 and P 7 a , the control system 200 will assume control over the motor 32 and will gradually decrease the speed of the motor as determined by the difference in temperatures sensed by the sensors 130 and 134 .
Referring further to FIG. 3A, when a 24 volt AC signal is applied across terminals P 5 and P 7 a and diode D 170 , resistor R 690 , diode D 190 , capacitor C 150 and diode D 180 , the COOL RAMP circuit is disabled by way of reference terminal 233 which is connected to reference terminal 235 in FIG. 3 A. Under these operating conditions only temperatures rising above the sensor 132 temperature compared to the return air sensor 130 will affect motor speed. Temperatures sensed by the heat sensor 132 and cool air sensor 134 , if less than the temperature sensed by the return air sensor 130 , will only maintain a HEAT RAMP circuit output voltage at its minimum. This will cause the motor 32 to operate at zero rpm or at its minimum speed, depending on whether a cutoff or minimum speed mode is chosen.
Referring now to FIG. 3B, an OVERVOLTAGE RAMP AND SENSOR PROTECTION circuit is provided which includes capacitor C 70 , resistors R 260 , R 270 , R 310 and R 340 , amplifier U 4 :A 1 , diode D 90 and resistor R 330 for the HIGH RAMP output. The OVERVOLTAGE RAMP AND SENSOR PROTECTION circuit further includes resistors R 470 , R 500 , R 440 , R 480 , amplifier U 4 :B 1 and diode D 120 , for the ZERO RAMP. Resistors R 550 , R 620 , R 560 , R 590 , amplifier U 4 :C 1 and diode D 130 comprise the circuit of a RETURN AIR SENSE OPEN output. Resistors R 660 , R 680 , R 650 , R 670 , amplifier U 4 :D 1 and diode D 160 comprise the circuit for the RETURN AIR SENSOR SHORT output. The purpose of these circuits is to cause the motor 32 to be driven at full speed if either of the sensors 130 , 132 or 134 is in an open or a shorted operating condition, or if the HEAT/COOL RAMP is at zero or greater than the ramp voltage boundaries.
Referring further to FIG. 3B, amplifier U 4 :A 1 receives an input signal on its positive terminal by way of conductor 237 which is connected to the HEAT/COOL RAMP of FIG. 3 A. An output signal from amplifier U 4 :A 1 goes high when the COOL RAMP or HEAT RAMP circuit output signals equal or exceed a differential temperature trip point. In fact, amplifiers U 4 :A 1 , U 4 :B 1 , U 4 :C 1 and U 4 :D 1 are all operable, when providing a high output signal, to cause motor 32 to run at full speed. The output signals from any one of these amplifiers is conducted via reference terminals 239 and 241 to the opto-isolator U 60 .
Referring further to FIG. 3B, an output signal from amplifier U 4 :B 1 goes high when the output from the HEAT RAMP or COOL RAMP circuits goes to zero. This occurrence would be the result of the cool sensor 134 being shorted or the heat sensor 132 going to an open condition. The output signal from amplifier U 4 :A 1 goes high when the output signal from the HEAT RAMP circuit or the COOL RAMP circuit goes high. This occurs when the cool sensor 134 has an open circuit condition or when the heat sensor 132 experiences a shorted condition. Still further, the output signal from amplifier U 4 :C 1 goes high when the return air sensor 130 is in an open condition and the output signal from amplifier U 4 :D 1 goes high when the return air sensor is shorted. A signal from the return air sensor 130 is supplied to amplifiers U 4 :C 1 and U 4 :D 1 via reference terminals 243 and 245 . Reference terminals 247 and 249 , FIG. 3A, are also connected to reference terminal 245 and impose signals on amplifiers U 1 :C 1 and U 3 :B 1 .
Referring further to FIG. 3A, the HEAT RAMP circuit receives a variable voltage signal from the heat sensor 132 by way of a buffer amplifier U 3 :C 1 . The output of the HEAT SENSE circuit, the junction of resistors R 720 and R 430 , is connected to the HEAT RAMP circuit through resistor R 390 and buffer amplifier U 3 :C 1 . Amplifier U 3 :A 1 is a differential amplifier and its output voltage is determined by the difference between the heat sensor voltage output signal and the return air sensor voltage output signal which is the output signal from the junction of resistors R 190 and R 210 as imposed on reference terminal 249 . Amplifier U 3 :B 1 is also a buffer amplifier for the return air sensor voltage output signal. A variable voltage output signal from amplifier U 3 :A 1 and diode D 100 is thus imposed on reference terminals 212 and 214 through resistors R 580 and R 630 .
Referring still further to FIG. 3A, the COOL RAMP circuit includes resistors R 20 A, R 30 A, R 50 A, R 70 , R 80 , R 10 A, R 11 A, capacitors C 10 A and amplifiers U 1 :B 1 , U 1 :C 1 and U 1 :D 1 as well as diode D 10 A. Capacitors C 10 A and C 90 minimize the effect of a step function at the output of the cool sensor 134 or heat sensor 132 to prevent motor lockup and also to minimize unwanted electrical noise from entering the circuit. The output signal from the cool sensor 134 is connected to the COOL RAMP circuit through resistor R 70 to buffer amplifier U 1 :B 1 whose output is imposed on amplifier U 1 :D 1 . Amplifier U 1 :D 1 is a difference amplifier whose output signal is determined by the difference between the cool sensor voltage output signal and the return air sensor voltage signal at the junction of resistors R 190 and R 210 . Amplifier U 1 :C 1 is a buffer amplifier for the output signal of return air sensor 130 . The output signal from the COOL RAMP circuit is by way of amplifier U 1 :D 1 through diode D 10 A to conductor 221 and to reference terminal 212 by way resistors R 580 and R 630 . The output signal from the junction of resistors R 60 and R 100 is also imposed on amplifier U 1 :A 1 by way of reference terminals 253 and 255 to disable the HEAT RAMP circuit when the system 200 is operating in a cooling mode. Conversely, the output of the heat sensor 132 , as measured at the junction of resistors R 720 and R 430 , is imposed on reference terminals 257 and 259 and amplifier U 3 :D 1 to disable the COOL RAMP circuit. The ramp circuits will generate a voltage signal as the differences between the return air sensor voltage and the heat sensor voltage or cool sensor voltage pass outside of a dead band of approximately 5° F. The cooling temperature signal output must be below the referenced temperature by about 2.5° F. and the temperature signal from the heat sensor must be above the reference temperature by about 2.5° F. When either condition exists, the ramp voltage signal imposed on terminal 221 will increase starting just outside the deadband.
The operation of the control systems 20 and 200 to vary the speed of a fan motor for a forced air air conditioning system for the advantageous purposes set forth herein is believed to be understandable to those of ordinary skill in the art based on the foregoing description. A correlation table of the components of the systems 20 and 200 is set forth hereinbelow. Certain ones of the circuit components shown in the drawing and included in the correlation table are not discussed in detail but are believed to be understandable to those of ordinary skill in the art. Preferred values and commercial part numbers for certain components are identified also.
CORRELATION TABLE
COM-
MERCIAL
ITEM
PART NO.
VALUE
C1
.1
μF
C2
100
μF
63
V
C4
. 22
μF
C5
.1
μF
C6
.1
μF
C7
.1
μF
250
V
C8
0.1
μF
C9
.1
μF
C10
.1
μF
C10A
0.47
μF
C11
10
μF
25
V
C12
10
μF
25
V
C13
.47
μF
C14
.47
μF
C20
0.1
μF
C30
0.1
μF
C40
0.1
μF
C50
100
μF
63
V
C60
0.1
μF
C70
0.1
μF
C80
0.1
μF
C90
0.47
μF
C100
0.22
μF
C110
0.1
μF
C120
.1
μF
250
V
C130
0.1
μF
C140
0.1
μF
C150
10
μF
25
V
C160
10
μF
25
V
D1
IN4148
D2
IN4003
D3
IN4148
D4
IN4148
D5
IN4742A
D6
IN4148
D7
IN4148
D8
IN4148
D9
IN4148
D10
IN4148
D10A
IN4148
D11
IN4148
D12
IN4148
D13
IN4148
D14
IN4148
D15
IN4148
D40
IN4148
D50
IN4003
D60
IN4148
D70
IN4148
D80
IN4742A
D90
IN4148
D100
IN4148
D110
IN4148
D120
IN4148
D130
IN4148
D140
IN4148
D150
IN4148
D160
IN4148
D170
IN4148
D180
IN4148
D190
IN4742A
D200
IN4148
D210
IN47742A
D300
IN4148
Q1
BTA 6
R1
1M
R2
475K
R3
10K
R4
475K
R5
1M
R6
1M
R7
26.7
K
R8
1M
R9
10K
THERMISTOR
R10
R10A
R11
10K
THERMISTOR
R11A
R12
10K
R13
825K
R14
1M
R15
750. ½
W
R16
1M
(RP2.4)
R17
1.24K
R18
825K
R19
25.5K
R20
1M
R20A
1M
R21
499K
R22
5K
R23
634K
R23A
R24
1M
R24A
R25
1M
R26
2.74M
R27
100K
R28
22.1K
R29
44.2K
R30
470 ½
W
R30A
R31
7.5K
R32
510 2
W,
METAL
OXIDE
R32A
R33
1M
R34
1M
R35
10K
R36
6.04K
R37
499
R37A
R38
10.5K
R39
10K
R40
200K
R41
7.5K
R42
100K
R43
10K
R44
20.5K
R45
10K
R46
100K
R47
1M
R48
1M
R49
3.48K
R50
10K
R50A
10K
R51
2K
R70
7.5K
R71
100K
R80
{ }
R90
200K
R100
R120
100K
R130
R140
1M
R150
1M
R160
10.5K
R170
1M
R180
10K
R190
R200
6K
2
W
R210
10K
R220
1M
R250
1M
R260
10K
R270
3.48K
R280
R290
R300
1M
R310
1M
R330
2K
R340
1M
R350
2.74M
R360
R380
R390
1M
R400
1M
R410
1M
R420
100K
R430
R440
1M
R450
10K
R460
20.5K
R470
R480
1M
R490
470 ½
W
R500
R510
10K
R520
10K
R530
63.4K
R540
5K
R550
R560
1M
R570
510 2
W.
METAL
OXIDE
R580
25.5K
R590
1M
R600
6.04K
R610
499
R620
R630
22.1K
R640
44.2K
R650
1M
R660
R670
1M
R680
R690
7.5K
R700
7.5K
R710
100K
R720
U1:A
LM2902
U1:A1
LM2902N
U1:B
LM2902
U1:B1
U1:C
LM2902
U1:C1
LM2902N
U1:D
LM2902
U1:D1
LM2902
U2:A
LM2902
U2:A1
LM2902
U2:B
LM2902
U2:B1
LM2902
U2:C
LM2902
U2:C1
LM2902
U2:D
LM2902
U2:D1
LM2902
U3
MOC3052N
U3:A1
LM2902
U3:B1
LM2902N
U3:C1
U3:D1
LM2902N
U4:A
LM2904
U4:A1
LM2904
U4:B1
LM2902N
U4:C1
LM2902N
U4:D1
LM2902N
U5:A1
CD4066
U60
MOC3052N
Although preferred embodiments of the invention have been described in detail herein, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims. | A fan motor speed control system for controlling the fan motor speed of an air conditioning system includes a power output circuit including a power triac which is turned on and off by an opto-isolator connected to a pulse generator circuit for varying an AC voltage waveform imposed on the fan motor. The pulse generator circuit is connected to heating and cooling ramp circuits and a minimum speed circuit to provide a variable voltage signal imposed on the pulse generator circuit corresponding to the temperature difference sensed by a return air sensor and a heating or cooling sensor or by separate heating and cooling sensors disposed adjacent respective heating and cooling heat exchangers of the air conditioning system. An adjustable minimum speed circuit and a cutoff circuit are provided to control motor minimum speed or motor shutoff when a predetermined minimum speed is reached to prevent motor bearing failure or overheating. Sensor protection circuits in the control system operate to drive the motor to full speed if any of the temperature sensors experience an open or short circuit condition. The control system circuit maximizes air conditioning system efficiency by capturing additional heating or cooling effect, reduces noise associated with motor startup and shutdown, and reduces rapid change in the sensed temperature in the air conditioned space during motor startup and shutdown. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is entitled to the benefit of Canadian Patent Application 2,231,428 filed on Jun. 30, 2000.
BACKGROUND
1. Field of the Invention
This invention relates to firearms, specifically to a trigger lock for a firearm to prevent the trigger device from movement.
2. Description of the Prior Art
Unauthorized or inadvertent discharge of a firearm is a problem that injures or kills many people. This problem is particularly acute and distressing in the case of children who play with their parent's firearm. The prior art reveals many attempts to alleviate this problem by selectively disabling the gun by locking blocking devices to obstruct the barrel of the gun or by locking trigger blocking or guarding devices to the trigger guard.
One such prior art device is described in U.S. Pat. No. 5,910,002 issued to Hunter on Jun. 8, 1999 and entitled “Gun Trigger Safety Device”. Hunter describes a trigger-blocking plug that conforms to the space behind the trigger to prevent the weapon from firing. However, the Hunter device cannot be securely locked to the weapon to disable it and therefore it is unsuitable for securing safe a weapon in a home or for long periods of time.
Another attempt at a plug-type tigger safety device is described in U.S. Pat. No. 5,724,760 issued to Langner on Mar. 10, 1998 and entitled “Trigger Safety Device”. Langer discloses a design that permits a trigger blocking device to be locked to the weapon. Langner's device includes a horizontal extension from one side of the trigger-blocking plug that includes a hole at right angles to the plug's axis and through which a small padlock may be engaged. Since the padlock shackle is disposed at right angles to the plug, it engages a side of the trigger guard and trigger to prevent unauthorized removal of the plug from behind the trigger. However, the padlock shackle may be used to twist and break the extension and thereby free the device from the firearm. As well, Langner teaches a two-piece system comprising a lock and a separate trigger blocking device leaving the smaller trigger blocking device vulnerable to misplacement and loss. Additionally, the separate padlock dangles freely from the firearm and therefore may scratch the finish of the gun.
SUMMARY
In accordance with my present invention there is provided a trigger lock for a firearm having a barrel, a frame, a handle and a trigger depending from the bottom of the frame and disposed in front of the handle. The trigger lock comprises a trigger lock body comprising a trigger blocking portion for placement behind the trigger to prevent rearward movement of the trigger to a firing position. Also included is a flange adjacent to and integral with the trigger blocking portion for positioning in an abutting relationship with one side of the trigger guard to prevent lateral and twisting movement of the trigger blocking portion. Also included is a padlock having a locking body with a top surface and a U-shaped shackle. The shackle has a curved head from which depends a first leg lockably disengagable from the top surface of the locking body and a second leg pivotally and permanently engaged to the top surface of the locking body. Means for removably mounting the guard body in a cooperative frictional engagement on to the free leg of the shackle is also provided. This permits the guard body and shackle first leg combination to be positioned horizontally behind the trigger as a single piece so that when the trigger blocking portion is behind the trigger and the padlock is closed, the top surface of the padlock creates an abutment abutting against the trigger guard opposite the first flange preventing movement of the trigger blocking portion.
Objects and Advantages
Accordingly, several objects and advantages of my invention are:
a. to provide a trigger lock that overcomes the deficiencies observed in the prior art;
b. to provide a trigger lock that permits the locked gun to be safely stored in a loaded condition;
c. to provide a trigger lock that can be quickly fitted to and removed from the gun;
d. to provide a trigger lock that may be easily adapted to fit a wide variety of existing firearms;
e. to provide a trigger lock that is difficult for unauthorized persons to remove;
f. to provide a simplified gun trigger lock that is inexpensive to manufacture using off the shelf padlocks; and,
g. to provide a trigger lock that does not scratch the gun to which it is affixed.
A further object and advantage of my invention is to provide a trigger lock that can be mounted to the shackle of a commercial padlock without further modification to the padlock and create a single piece device that is difficult to misplace or loose.
Still further objects and advantages of my invention will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in perspective view a padlock suitable for use as part of my invention in the closed position.
FIG. 2 illustrates the same padlock in another perspective view for use as part of my invention in the open position.
FIG. 3 illustrates a typical trigger guard in side view that my invention may be adapted to.
FIG. 4 illustrates in perspective view one embodiment of the locking body of my invention.
FIG. 5 illustrates the same embodiment of the locking body of my invention shown in FIG. 4 from a different perspective.
FIG. 6 illustrates one embodiment of my invention mounting in a sliding engagement with a shackle of a padlock suitable for use in my invention.
FIG. 7 illustrates one embodiment of my invention mounted on a shackle of a closed padlock and placed behind the trigger of a firearm.
FIG. 8 illustrates the same embodiment as that in FIG. 7 from a different perspective.
FIG. 9 illustrates another embodiment of the locking body of my invention.
FIG. 10 illustrates yet another embodiment of the locking body of my invention.
FIG. 11 illustrates the same embodiment of FIG. 10 from a different perspective.
DETAILED DESCRIPTION
One advantage of my invention is that it is used in combination with a suitable commercially available padlock without having to make any modifications to the padlock. One example of padlocks that work well with my invention are those manufactured under the trademark MASTER™. These padlocks are known to be very strong and tamper resistant and therefore well suited for securing a firearm.
FIG. 1 and FIG. 2 illustrates padlock 10 suitable for use with my trigger lock in the closed position and open position respectively. Padlock 10 has a top surface 8 and is comprised of locking body 12 , which engages both ends of shackle 14 within a locking socket 18 and, swivel socket 16 . Shackle 14 is typically hardened steel rod formed into a “U” shaped shackle comprised of a semi-circular head 20 and a first leg 22 and a second leg 24 depending from the head. Means for locking and unlocking the shackle from the locking body is shown in FIG. 2 as key 26 inserted into key lock 28 . A padlock with a combination locking means may also be used.
When the padlock is opened, first leg 24 is disengaged from the locking socket 18 of the locking body 12 it is free to pivot about locking socket 16 in which second leg 24 is permanently secured.
FIG. 3 illustrates a common trigger guard 54 as might be found on a variety of typical firearms. It is to be understood that my invention is easily adaptable to almost any manufacture of handgun having a trigger 48 and trigger guard 54 similar to that illustrated here. The trigger guard 54 surrounds trigger 48 . The trigger 48 has a front surface 50 , a rear surface 52 , a first side 41 and a second side 43 . The trigger guard has a first side 56 and a second side 58 . Void 60 is created between the rear surface of the trigger 52 and the trigger guard 54 . Typically the width of the trigger is slightly less than the width of the trigger guard.
FIG. 4 and FIG. 5 illustrate one embodiment of the trigger lock body 70 of my invention from different perspectives. Locking body 70 comprises a trigger blocking portion 72 for placement behind the trigger 48 of a firearm to prevent rearward movement of the trigger 48 to a firing position. The trigger blocking portion 72 has a head 73 (shown as hash marked portion) and a body 75 and a width at least equal to the trigger but generally slightly wider than the width of the trigger. The trigger blocking portion 72 is configured to substantially fill the void 60 between the rear of the trigger 48 and the trigger guard 54 to prevent required movement of the trigger to a firing position. A flange 74 is placed adjacent to and integral with the trigger blocking portion 72 for positioning in an abutting relationship with side 56 of the trigger guard 54 thereby preventing lateral and twisting movement of the trigger blocking portion 72 . Stop member 76 is integral to the trigger blocking portion 72 and raised from the side 78 of the trigger blocking portion and is adapted to engage in an abutting relationship the side 43 of the trigger 48 . Stop 76 assists flange 74 to prevent lateral movement 73 of the locking body 70 within the trigger guard 54 . Alternatively, stop member 76 may be removed thereby leaving flange 74 to absorb twisting forces placed on the trigger lock body.
Still referring to FIGS. 4 and 5 the trigger blocking portion 72 comprises, a first side 78 , a second side 80 , a front surface 82 , a top surface 84 , a bottom surface 86 and a rear surface 88 . Front surface 82 is concave in shape and adapted to generally agree with the rearward convex-shaped surface of the trigger 48 . Rear surface 88 is convex in shape and adapted to generally agree with the concave-shaped trigger guard 54 . Top surface 84 is generally rounded and adapted to extend upwards towards the top of the trigger guard 54 so that it substantially fills void 60 and prevents rearward movement of the trigger 48 to a firing position. Bottom surface 86 is generally curved in a convex shape and tapered to a truncation 85 that extends downwards and forwards to the bottom of the trigger 48 to further fill void 60 .
Still referring to FIGS. 4 and 5, flange portion 74 comprises a first side 90 , a second side 92 , a front surface 94 , a rear surface 96 , a top surface 98 and a bottom surface 100 . At least 50% of first side 92 of flange 74 is attached to and integral with side 78 of the trigger blocking portion 72 . The bottom portion 93 (shown in the hash lines) of flange 74 extends below the bottom of the trigger guard 54 to inhibit lateral and twist movement of the trigger blocking portion 72 . Flange 74 is substantially rectangular in shape.
Shoulder portions 102 and 104 extend from the head portion (shown as 73 in the hashed area) of the trigger blocking portion 72 . They are contiguous with and integral to each side of the head 73 of trigger blocking portion 72 respectively and have the same top surface profile as the trigger blocking portion. The bottom surface 106 and 107 of shoulder 102 and 104 respectively are flat and parallel to the flat bottom surface 100 of the flange portion 74 .
Referring now to FIGS. 4, 5 and 6 together there is illustrated the manner in which the locking body 70 of my invention is removably and slidably mounted to the shackle 14 of a padlock 10 to advantageously form a single piece trigger lock. This greatly reduces the chances of losing the locking body when it is removed from the firearm. FIGS. 4, 5 and 6 illustrate that the locking body 70 has means for removable and slidingly mounting itself to leg 22 of the U-shaped shackle 14 of a padlock 10 . The means comprises an aperture 110 through the flange portion 74 and the trigger blocking portion 72 of the guard body 70 . The aperture 110 is sized to receive 24 of shackle 14 in frictional sliding engagement by using hand force. Once guard body 70 is placed onto the shackle leg 22 the locking tip 112 of the leg 22 is exposed beneath the shoulder portion 102 of the body 70 for lockable engagement with socket 18 in the locking body 12 of the padlock 10 . Also shown in FIGS. 4, 5 and 6 is groove 114 within the surface 90 of flange 74 . Groove 114 is adapted in shape receive the head 20 of the U-shaped shackle 14 . Groove 114 is sufficiently deep to enclose the head of the U-shaped shackle so that the top surface of the head 20 of the shackle 14 is substantially flush with the outside side surface of the flange 90 .
Referring now to FIG. 7 and FIG. 8, there is shown one embodiment of my invention locking body 70 mounted to the shackle 14 of a padlock 10 and the shackle 14 and locking body 70 combination placed behind the trigger 48 within trigger guard 54 . The blocking portion 72 is placed in sliding engagement behind the rear surface 52 of the trigger 48 so that rearward movement of the trigger to a firing position is prevented. Trigger stop 76 abuts against the side 43 of trigger 48 to prevent the locking body from sliding too far into the trigger guard. Flange 74 abuts against the side 56 of the trigger guard and also prevents any lateral movement of the locking body within the trigger guard. The stop 76 and the flange 74 also prevent any twisting movement of the locking body within the trigger guard 54 . It is important to note that one advantage of my invention is to place the shackle of the lock in combination with the locking body horizontally behind the trigger instead of hanging the padlock vertically beside trigger guard. This configuration prevents twisting of the lock and breaking of the locking body. It is virtually impossible to remove the combined shackle and locking body without having to cut the trigger guard away from the frame of the firearm or cut the shackle of the lock. It also prevents scratching of the firearm.
Shoulder portions 102 and 104 of the locking body 70 extend from both sides of the blocking portion 72 and are integral to the blocking portion. The shoulders to provide additional resistance to any attempt to twist the locking body from the behind the trigger. There is at least one shoulder although there may be two.
Still referring to FIG. 7 and FIG. 8, there is shown my invention mounted behind the trigger 48 with the padlock 10 closed and locked. The top surface 8 of the locking body 12 of the padlock 10 abuts against the opposite side 58 of the trigger guard 54 and forms an opposing abutment to flange 74 . In this manner the body 70 is sandwiched between the top surface of the padlock locking body 8 abutting against side 58 and flange 74 abutting against side 56 .
The embodiment of my invention shown in FIGS. 4 and 5 will accommodate many types of trigger and trigger guard configurations. However, some trigger and trigger guard configurations will demand that an inventory of trigger lock bodies by kept with each one configured to exactly fit a different make of firearm. For that reason, additional embodiments of my invention are described below.
Referring now to FIGS. 3 and 9 there is shown an alternate embodiment 120 of the locking body of my invention suited to firearms having a small void 60 behind trigger 48 .
The locking body 120 of this embodiment of my invention comprises a trigger blocking portion 122 for placement behind the trigger 48 to prevent rearward movement of the trigger to a firing position. The trigger blocking portion is configured to substantially fill the void 60 between the rear of the trigger 52 and the trigger guard 54 . A flange portion 124 is placed adjacent to and integral with the trigger blocking portion 122 for positioning in an abutting relationship with side 56 of the trigger guard 54 thereby preventing lateral and twisting movement of the trigger blocking portion 122 .
Still referring to FIG. 9 the trigger blocking portion 122 comprises, a first side 126 , a second side 128 , a front surface 129 , a top surface 130 , a bottom surface 132 and a rear surface 131 . Front surface 129 and rear surface 131 are both generally concave so that blocking portion 122 is generally ovular in shape with an axis 134 that is disposed at an angle 137 of less than 90 degrees to the horizontal axis 136 of flange 124 . Blocking portion 122 is adapted to substantially fill the void behind trigger 48 .
Referring to FIG. 9, flange portion 124 comprises a first side 140 , a second side 142 , a front surface 144 , a rear surface 146 , a top surface 150 and a bottom surface 148 . Side 128 of the blocking portion 122 is fixed to and integral with side 140 of flange 124 . The bottom surface 148 is adapted to extend below the bottom of the trigger guard 54 to inhibit lateral movement of the trigger blocking portion 122 . Flange 124 is substantially rectangular in shape.
Referring to FIGS. 6 and 9, there is illustrated the manner in which the locking body 120 of my invention is mounted to the shackle 14 of a padlock 10 to advantageously form a single piece trigger lock. The means comprises an aperture 152 through the flange 124 and the trigger blocking portion 122 of the guard body 120 . The aperture 150 is sized to receive leg 22 of shackle 14 in frictional sliding engagement by using hand force. Also shown in FIG. 9 is groove 154 within flange 124 . Groove 154 is adapted in shape receive the head 20 of the U-shaped shackle 14 . The groove is sufficiently deep to enclose the head of the U-shaped shackle so that the top surface of the head of the shackle is substantially flush with the outside side surface of the flange 124 . Body 120 is mounted to a padlock shackle and placed behind the trigger of a firearm substantially as shown in FIG. 6 .
Referring now to FIGS. 10 and 11 there is shown yet another embodiment of my invention. The locking body 180 comprises a trigger blocking portion 182 for placement behind the trigger of a firearm to prevent rearward movement of the trigger to a firing position. The trigger blocking portion may have a width equal to the trigger or slightly wider than the width of the trigger. The trigger blocking portion is configured to substantially fill the void 60 between the rear of the trigger 52 and the trigger guard 54 . A flange 184 is placed adjacent to and integral with the trigger blocking portion 182 for positioning in an abutting relationship with side 56 of trigger guard 54 thereby preventing lateral and twisting movement of the trigger blocking portion.
Still referring to FIGS. 10 and 11 the trigger blocking portion 182 comprises, a side 186 , a front surface 190 , a top surface 194 , a bottom surface 196 and a rear surface 192 . Front surface 190 is concave in shape and adapted to generally agree with the rearward convex-shaped surface of the trigger 48 . Rear surface 192 is convex in shape and adapted to generally agree with the concave-shaped trigger guard 54 . Top surface 194 is rounded and tapered and adapted to extend upwards towards the top of the trigger guard 54 so that the body 180 substantially fills void 60 . Bottom surface 196 is rounded and tapered and adapted to extend downwards towards the bottom of the trigger 48 again to fill void 60 .
Still referring to FIGS. 10 and 11, flange portion 184 comprises a first side 200 , a second side 202 , a front surface 204 , a rear surface 206 , a top surface 208 and a bottom surface 210 . Side 202 is partially contiguous and integral with the trigger blocking portion 182 . Flange 184 extends substantially below the bottom of the trigger guard 54 to inhibit lateral movement of the trigger blocking portion. Top surface 208 of flange 184 has a profile identical to that of the top surface 182 of the trigger blocking portion and a back surface 206 that is substantially planar. Bottom surface 210 of the flange is flat.
Shoulder portion 212 is contiguous with and integral to the first side 186 of the trigger blocking portion 182 and has generally semi-circular shape having a top surface 214 profile identical to the top surface profile 194 of the trigger blocking portion 182 and a bottom surface 216 that is flat and parallel with the flat bottom surface 210 of the flange portion.
Still referring to FIGS. 10 and 11 there is shown aperture 220 through the flange portion 184 and the trigger blocking portion 182 of the guard body 180 for mounting the body to the shackle of a padlock. Aperture 220 is sized to receive leg 22 of shackle 14 in frictional sliding engagement by using hand force. Once body 180 is placed onto the shackle leg 22 the locking tip 82 of the leg 22 is exposed beneath the shoulder portion 212 of the body 180 for lockable engagement with the locking body 12 of the padlock 10 . Also shown is groove 222 within the surface 200 of the flange portion 184 of the guard body 180 . The groove 222 is adapted in shape receive the head 20 of the U-shaped shackle 14 . The groove is sufficiently deep to enclose the head of the U-shaped shackle so that the top surface of the head of the shackle is flush with the outside side surface of the flange.
The body 180 mounts to a padlock shackle and behind the trigger 48 of a firearm as shown in FIG. 6 .
Although this description contains much specificity, these should not be construed as limiting the scope of the invention by merely providing illustrations of some of the embodiment of the invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. | A trigger lock for a firearm lock is disclosed comprising a trigger lock body having a trigger blocking portion. The trigger blocking portion has a head and a body for placement behind the trigger to prevent rearward movement of the trigger to a firing position. The trigger lock body includes a flange adjacent to and integral with the trigger blocking portion for positioning in an abutting relationship with the trigger guard thereby preventing lateral and twisting movement of the trigger blocking portion once placed behind the trigger. There is provided at least one shoulder portion extending laterally from the head of the body beyond the corresponding side of the trigger guard when the body is placed behind the trigger to resisting twisting motion. The trigger lock body mounts to a shackle of a padlock so that the body and padlock shackle to which it is mounted forms a unitary trigger guard for insertion behind the trigger. | 5 |
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] The invention relates to a device for packing flat articles in transport containers, in particular folded-flat folding boxes in casing cartons, including a feeder for feeding the flat articles in imbricated form, and a conveyor disposed downstream of the feeder as viewed in a travel direction of the flat articles. The conveyor has an at least approximately vertically extending end for discharging the articles into the transport containers at the filling location. Equipment is provided for further conveying the transport containers at the filling location.
[0002] German Published, Non-Prosecuted Patent Application 28 25 647, corresponding to UK Patent Application GB 2 022 558, discloses a device of the general type described in the introduction hereto, namely for packing folded-flat folding boxes in casing cartons, wherein a conveyor has a lowering rail and a pivoting rail, each with a revolving belt. The folding boxes, which are fed in imbricated form, are conveyed between the belts into casing cartons used as transporting containers. The lowering rail therein serves as an abutment, which interacts with the pivoting rail at the discharge location in order for the folding boxes to be guided as far as possible into a definitive position thereof in the transport container. The at least approximately vertically moveable lowering rail has a longitudinally displaceable switching rail fastened thereon in order to allow precise positioning of the lowering and pivoting rails in the transport container. The switching rail projects beyond the lowering rail in the downward direction and actuates a switch as soon as it is positioned on the base of the transport container. As a result, the operation of lowering the lowering and pivoting rails with a hydraulic drive is stopped at a defined distance from the base of the transport container. Adjustment of the distance, for example for adaptation to different folding-box formats, is only possible by a mechanical intervention in the construction of the conveyor.
[0003] German Published, Non-Prosecuted Patent Application 28 25 648, corresponding to UK Patent Application GB 2 030 952, likewise describes a device for introducing folding-box blanks into transport containers, wherein the blanks are guided between a top belt and a bottom belt of the conveyor. The bottom and top belts of the conveyor therein are driven by independent drives which are not specifically described. A further packing device of that type is described in German Published, Non-Prosecuted Patent Application 2 261 416. The bottom belt of the conveying configuration wraps around a drive roller and deflecting rollers, which define a curved conveying path. Specific details regarding the construction of the drives are also not disclosed therein.
SUMMARY OF THE INVENTION
[0004] It is accordingly an object of the invention to provide a device for packing flat articles in transport containers, in particular folded-flat folding boxes in casing cartons, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type, which reliably conveys and discharges flat articles at high speeds, for quick adjustment to different formats of the articles and/or transport containers and for allowing for wide-ranging automation and space-saving construction.
[0005] With the foregoing and other objects in view, there is provided, in accordance with the invention, a device for packing flat articles in transport containers, comprising a feeder for feeding the flat articles in imbricated form and a conveyor disposed downstream from the feeder, as viewed in travel direction of the flat articles. The conveyor has an at least approximately vertically extending end for discharging the articles into the transport containers for filling the transport containers therewith at a filling location.
[0006] Equipment for further conveying the transport containers at the filling location includes two lateral belt conveyors disposed at the filling location for moving the transport containers forward during the filling thereof with the articles.
[0007] In accordance with another feature of the invention, each of the two belt conveyors includes two conveying belts drivable independently of one another and being formed of vertically extending conveying strands respectively disposed behind one another.
[0008] In accordance with a further feature of the invention, the belt conveyors are mounted in a transversely adjustable manner.
[0009] In accordance with an added feature of the invention, the conveying belts have respective drives formed as electric servomotors.
[0010] In accordance with a concomitant feature of the invention, the flat articles are folded-flat folding boxes, and the transport containers are casing cartons.
[0011] Thus, the object of the invention is achieved by providing two lateral belt conveyors at the filling location of the transport containers for moving the transporting containers forward during the filling operation. In a preferred embodiment, each belt conveyor has two conveying belts which are driven independently of one another. This provides the advantage that two independent conveyors are provided behind one another, and makes it possible for empty casing cartons to be fed by the two first conveying belts, while filled casing cartons can be transported away by the second conveying belt. The belt conveyors are preferably mounted in a transversely adjustable manner, with the result that they can be adjusted individually to transport containers of different widths. In a further preferred embodiment, the drives for the conveying belts are electrically controllable servomotors which, in turn, is advantageous in view of the capability that is then provided for automating the filling location.
[0012] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0013] Although the invention is illustrated and described herein as embodied in a device for packing flat articles in transport containers, in particular folded-flat folding boxes in casing cartons, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0014] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a diagrammatic, side-elevational view of a packing device according to the invention;
[0016] [0016]FIG. 2 is a plan view of the packing device wherein individual constituent parts are illustrated diagrammatically;
[0017] [0017]FIG. 3 is a side-elevational view of a feeder for feeding casing cartons to a filling device;
[0018] [0018]FIG. 4 is a front-elevational view of FIG. 3;
[0019] [0019]FIG. 5 is a front, side and top perspective view of FIG. 3;
[0020] [0020]FIG. 6 is an enlarged, fragmentary view of FIG. 1, showing the conveyor thereof;
[0021] [0021]FIG. 7 is an enlarged, fragmentary view of FIG. 6, for clarifying the filling operation;
[0022] [0022]FIG. 8 is a front, side and top perspective view of the beginning of the conveyor;
[0023] [0023]FIG. 9 is a front, side and top perspective view of the folding-box feeder disposed upstream of the conveyor and showing the detailed construction thereof;
[0024] [0024]FIG. 10 is an enlarged, fragmentary cross-sectional view of the conveyor of the folding-box feeder; and
[0025] [0025]FIG. 11 is a top, side and front perspective view of the belt conveyors at the filling location.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen an exemplary embodiment of a packing device serving for packing folded-flat folding boxes 1 in casing cartons 2 . The packing device is disposed downstream of a folding-box adhesivebonding machine, wherein folding boxes are produced from blanks.
[0027] The packing device starts with a folding-box feeder 3 , to which the folded-flat folding boxes 1 are fed in imbricated form from the folding-box adhesive-bonding machine. The feeder 3 has, as conveyors, two belts 4 , whereon the folding boxes 1 are conveyed in a horizontally disposed condition. The feeder 3 illustrated in FIGS. 1, 2 and 9 is preferably constructed in such a way that the folding boxes 1 are conveyed further either in a rectilinear condition, without being rotated, or in a condition wherein they have been rotated through 90° to the lefthand or righthand sides of the respective figures. This makes it possible for the folding boxes 1 to be packed in the casing cartons 2 in an upright condition either with the leading edge or one of the side edges thereof at the bottom of the respective figure. If the blanks 1 are to be rotated through 90°, they are supplied to the belts 4 via a lateral roller conveyor 5 with a conveying section curved through 90° and, during transfer, they are aligned on a stop 6 which is parallel to the belts 4 and can be adjusted transversely to different box formats. If the folding boxes 1 are to be conveyed further by the folding-box adhesive-bonding machine in a rectilinear state, without being rotated, they are fed centrally in the direction of an arrow 7 . In order for the respectively desired supply inlet 5 or 7 to be adjustable or settable, the feeder 3 and the rest of the packing device are mounted in such a way that they can be adjusted transversely on rollers 8 , as illustrated in FIG. 1.
[0028] The feeder 3 illustrated in FIG. 2 allows folding boxes 1 to be conveyed further only in a rectilinear condition or in a condition wherein they have been rotated through 90° to the righthand side of FIG. 2. If rotation through 90° to the lefthand side is also to be permitted, the feeder 3 has, on the second longitudinal side, i.e., at the top in FIG. 2, a further roller conveyor, of which the conveying section runs rotatively through 90° to the lefthand side of the figure.
[0029] The folding boxes are transferred from the feeder to a conveyor 9 which includes, as conveying elements, at least one pair of belts with a top belt 27 , 28 and a bottom belt 29 , 30 , between which the folding boxes 1 are retained and conveyed. The conveying section of the conveyor 9 initially curves upwardly and then downwardly, and terminates with an approximately vertical profile at the filling location, at which the folding boxes 1 are packed in an upright condition in the casing cartons 2 .
[0030] [0030]FIG. 2 is a plan view of the configuration of the various conveyors by which empty casing cartons 2 are fed to the filling location at the end of the conveyor 9 , and cartons 2 filled with folding boxes are transported away.
[0031] It is an important feature for the invention that the empty casing cartons 2 , which are to be filled, be fed to the filling location in a rectilinear condition counter to the transporting direction of the folding boxes 1 . The feeding direction is represented by an arrow 12 in FIG. 2. For this purpose, the packing device has, downstream from the filling location, as viewed in the conveying direction of the boxes 1 , a belt conveyor 14 which conveys in the direction of the arrow 12 , and whereon the empty casing cartons 2 are positioned from behind by an operator represented at reference numeral 15 . The belt conveyor 14 , which is provided with a belt drive, transfers the empty casing cartons 2 to two lateral belt conveyors 16 and 17 , which extend through the filling region by way of vertically running belts. The two belt conveyors 16 and 17 , which are respectively movable transversely by a drive, act upon the sides of the casing carton 2 at the respective bottom and firmly clamp the carton therebetween. For filling purposes, the end of the conveyor 9 is moved into the casing carton 2 . During the filling operation, the two belt conveyors 16 and 17 move the casing carton 2 farther at the required speed, in order for the boxes to be disposed in the casing carton 2 in a condition wherein they stand in a row directly adjacent one another. In order to ensure that the casing carton 2 can be moved forward exclusively via the belt conveyors 16 and 17 during the filling operation, freely rotatable rollers 18 are disposed as a supporting surface in the filling region, so that the casing cartons 2 stand on the rollers 18 . The belt conveyors 16 and 17 are followed, as viewed in the transporting direction of the casing carton 2 , by a roller conveyor 19 which has driven rollers, and further transports the filled cartons 2 .
[0032] Hold-down bars 10 and 11 are preferably disposed along the conveying path of the casing cartons 2 to as far as the filling location. The hold-down bars force the cover flaps of the casing cartons 2 outwardly and thus keep the cartons 2 in the open position.
[0033] The two lateral belt conveyors 16 and 17 are illustrated in greater detail in FIG. 11, and move the casing cartons 2 forward during the filling operation. The two belt conveyors 16 and 17 are preferably constructed in a mirror-inverted manner relative to one another and are, respectively, individually mounted so as to be adjustable transversely to the transporting direction thereof, by a non-illustrated linear drive. Each belt conveyor 16 , 17 preferably has two conveying belts 80 and 81 , which are driven independently of one another and of which the conveying strands run vertically, respectively, and are disposed in alignment behind one another. Each of the revolving conveying belts 80 , 81 is deflected by deflecting rollers 82 , 83 which are fastened, by way of vertical spindles, on a common longitudinal carrier 84 so that the conveying strand, respectively, on the inside, runs outside the region of the longitudinal carrier 84 . Each conveying strand is supported on the rear side thereof by resilient elements 86 . Each longitudinal carrier 84 is adjustable transversely by a linear drive, with the result that the two belt conveyors 16 , 17 can be moved towards one another and away from one another in order to retain a casing carton 2 in a clamped condition. Each conveying belt 80 , 81 of a belt conveyor 16 , 17 is connected to a rotary drive 85 , which drives one of the deflecting rollers 83 via a mitre gear. The two-part form of each belt conveyor 16 , 17 offers the advantage that two independent conveyors are provided behind one another. This makes it possible for empty casing cartons to be fed by the two first conveying belts 80 , while filled casing cartons 2 are transported away by the second conveying belts 81 . The drives 85 used for the conveying belts 80 , 81 are preferably electric servomotors which allow precise control of the advancement of a casing carton 2 during the filling operation.
[0034] The construction of the conveyor 9 is illustrated in greater detail in FIG. 6. It has, at the end thereof, a lowerable pivoting rail 32 and a lowerable rail 22 that is lowerable in an at least approximately vertical movement to as far as the base 23 of a casing carton 2 . FIG. 6 illustrates the phase position wherein the rail has been moved into the carton 2 .
[0035] Fastened to the stationary mounting of the vertically lowerable rail 22 is a sensor 24 which, in a contactless manner, determines the distance between the vertically bottom end of the vertically lowerable rail 22 and the base 23 of the casing carton 2 . The sensor 24 that is preferably used is an ultrasonic sensor which is fastened to the load-bearing structure of the conveyor 9 via an angle plate 26 . The sensor 24 permits the distance between the end of the vertically lowerable rail 22 and the base 23 of the casing carton 2 , or a layer of boxes 1 which is already located in the casing carton, to be adjusted automatically.
[0036] The conveyor 9 has at least one driven pair of belts including a top belt 27 , 28 and a bottom belt 29 , 30 . The boxes 1 are conveyed in a condition wherein they lie horizontally between the respective belts 27 , 29 and 28 , 30 and are retained thereby. It is preferable for two driven pairs of belts to be disposed behind one another along the conveying section, it being possible for the top belts 27 , 28 and the bottom belts 29 , 30 , respectively, thereof to be driven independently of one another. In the preferred embodiment illustrated in the figures, the conveyor 9 has two conveying sections with, respectively, two separate belts 27 , 29 and 28 , 30 , each belt 27 , 28 , 29 , 30 having a dedicated independent drive 31 . The drives 31 which are used are electrically operated, controllable servomotors which allow precise control of the respective belt speed. The top belt 28 of the second conveying section is mounted on the vertically lowerable rail 22 , and the associated bottom belt 30 is mounted on the pivoting rail 32 .
[0037] Dividing the conveying section of the conveyor 9 into two sub-sections offers the advantage that, respectively, the predetermined number of boxes 1 of one layer can be deposited in casing cartons 2 by the second pair of conveying belts 28 , 30 , while the boxes 1 for the next layer are accumulated and held back in the first pair of conveying belts 27 , 29 . The supplying of the boxes 1 into the casing cartons 2 can be interrupted in order to move the vertically lowerable and pivotable rails 22 and 32 , respectively, into the position which is necessary for depositing the next layer or in order to convey up a new empty casing carton.
[0038] In order that the vertically lowerable rail 22 and the pivotable rail 37 may be lowered into a casing carton 2 , they are each provided with a separate lifting drive 36 , 38 . It is also preferable for the drives 36 , 38 to be electrically operated, controllable servomotors which allow precise control of the lowering movement. FIG. 7 illustrates the vertically lowerable rail 22 and the pivotable rail 32 in the operating position thereof.
[0039] The region of the belt conveyor 14 which conveys the casing cartons 2 to the filling location is illustrated in greater detail in FIGS. 3 to 5 . The belt conveyor 14 has a conveying belt 40 which corresponds, in terms of width, at least to the width of a casing carton 2 . The belt drive that is used is a servomotor, which drives the outlet-side deflecting roller 42 of the belt 40 . On the inlet side, the conveying section is bounded by the deflecting roller 41 of the belt 40 .
[0040] Disposed at a slight distance above the conveying plane of the belt 40 are two longitudinal carriers or support beams 44 whereon, respectively, a row of guide rollers 43 are mounted so as to be freely rotatable at a distance apart from one another. The spindle of each roller 43 is inclined in the conveying direction at an acute angle to the vertical. The longitudinal carriers 44 with the rollers 43 fastened thereon are adjustable transversely so that the rollers, respectively, guide a casing carton 2 in the bottom region of the side walls. The inclination of the rollers 43 causes the casing carton 2 , which is conveyed by the belt 40 , to be forced onto the belt 40 . The increased contact pressure improves the conveying and, at the same time, prevents the base flaps of the casing carton 2 from opening and forcing the latter upwardly. Because the base flaps of the casing carton 2 are pressed flatly onto the belt 40 , the planar base of the casing carton 2 is made available to the distance or spacing sensor 24 as a defined reference surface for distance-determining purposes.
[0041] At least one of the longitudinal carriers or support beams 44 is mounted so as to be adjustable transversely, with the result that the distance between the two longitudinal carriers or support beams 44 can be set to different casing-carton widths.
[0042] In the simplest form, the packing device includes only the aforedescribed parts with the conveying sections 14 , 18 and 19 . If the cartons 2 are to be filled with a number of layers of boxes 1 above one another and/or with several rows of boxes beside one another, an operator removes the not yet completely filled casing cartons from the roller conveyor 19 , carries them back to the belt conveyor 14 and repositions them there for the next filling operation. Completely filled casing cartons are transported away. This straightforward embodiment offers the advantage that the packing device is no wider than the upstream folding-box adhesive-bonding machine. It can thus also be used for very constricted space conditions. If there is sufficient space in the widthwise direction, use can be made thereof for transporting the casing cartons back automatically, as is illustrated with regard to the embodiment according to FIG. 2.
[0043] In the embodiment of FIG. 2, transversely running transporting belts 20 are disposed between the rollers of the roller conveyor 19 . It is possible for the transporting belts to be rendered inactive by being lowered beneath the conveying plane of the roller conveyor 19 , and to be activated by being raised above this conveying plane. The rollers of the roller conveyor 19 extend transversely beyond the filling region to such an extent that, on the ends thereof, casing cartons 2 can be transported back, past the filling location, in the direction counter to the filling direction. Following the roller conveyor 19 , alongside the filling location, is a further roller conveyor 21 , of which the conveying section extends, parallel and in the opposite direction to the conveying sections of the conveyors 14 , 16 , 17 , into the region of the start of the belt conveyor 14 , and thus forms the end of the packing device on this side. At this end, the conveying section of the roller conveyor 21 is connected to the start of the belt conveyor 14 via a further, transversely conveying roller conveyor 220 . This makes it possible, for an automated multilayered filling operation, for cartons to be conveyed, revolving or circulating through the filling location a number of times. In this advantageous embodiment, all that is required is for the operator 15 to position empty cartons on the belt conveyor 14 and to remove filled cartons from the roller conveyor 21 . It is also possible for these two manual operations to be automated by the attachment of corresponding conveyors. It is also advantageously possible to place further additional subassemblies along the conveying sections of the conveyors 21 and 22 , for example units by which the casing cartons are set in an upright position and opened, or units for closing the filled cartons.
[0044] The transition between the folding-box feeder 3 , which is illustrated in FIG. 9, and the conveyor 9 is configured as an accumulating and transfer device 50 , of which the parts fastened on the conveyor 9 are illustrated on an enlarged scale in FIG. 8. The accumulating and transfer device 50 has the task of collecting a given number of boxes 1 and transferring them in imbricated form, with a pre-set degree of overlapping, to the belts 27 , 29 of the conveyor 9 . For this purpose, the boxes 1 are conveyed continuously towards the start of the conveyor 9 by the belts 4 of the feeder 3 .
[0045] The accumulating and transfer configuration 50 includes an imbricating roller 51 which is disposed at the bottom at the start of the conveyor 9 and, at the same time, forms the inlet-side deflecting roller of the bottom conveying belt 29 . The imbricating roller 51 has the task of conveying between the conveying belts 27 , 29 , respectively, the first box of an assembled stack or pile accumulated in front thereof. The conveying belt 29 which runs around it is guided in a loop to the following deflecting roller 52 , which bounds the conveying section of the conveyor 9 , with the result that the conveying section is interrupted slightly at the bottom. The position of the imbricating roller 51 relative to the deflecting roller 52 determines the degree of overlapping by which the boxes 1 are drawn off from the feeder 3 . The imbricating roller 51 is thus mounted in a pivotable bearing part 53 in order that the degree of imbrication can be adjusted to the desired or nominal value via the position of the imbricating roller 51 .
[0046] A hold-down bar 54 , which extends counter to the conveying direction of the boxes 1 , is fastened above the imbricating roller 51 , on the conveyor 9 . The hold-down bar 54 has the task of holding the boxes 1 , which are accumulated upright on edge or edgewise, at the top edge thereof. The distance thereof from the belts 4 of the feeder 3 is adjusted to the box width. Together with the ends of the belts 4 , the hold-down bar 54 forms an accumulating section 55 , as can be seen from FIG. 1. Because the boxes 1 accumulating in the accumulating section 55 are positioned increasingly vertically as they increase in number, the minimum distance between the top edges of the boxes 1 and the hold-down bar 54 forms a measure of the number of accumulating boxes 1 . In order to measure the length of the accumulating stack of boxes and to control the draw-off speed of the conveying belts 27 , 29 in dependence thereon, an electromechanical sensor is integrated in the hold-down bar 54 for determining the height of the stack of boxes between the belts 4 and the hold-down bar 54 , and thus the number of accumulating boxes 1 .
[0047] Fastened at the end of the hold-down bar 54 is an elastic imbricating finger 56 which extends towards the bottom transporting belt 29 . The distance between the imbricating finger 56 and the bottom transporting belt 29 is adjusted to the thickness of the imbricated line of blanks. As the first box 1 of the accumulating stack of boxes is conveyed away, the next-following box 1 is held back by the imbricating finger 56 in order not to be drawn along by the first box 1 . The hold-down bar 54 with the imbricating finger 56 fastened thereon is mounted in a height-adjustable manner, in order that the position thereof may be adapted to different box widths.
[0048] The positions of the hold-down bar 54 , with the imbricating finger 56 , and of the imbricating roller 51 can preferably be adjusted in a coupled manner with one another, as is illustrated in FIGS. 6 and 8. This offers the advantage that a changeover of the accumulating and transfer configuration 50 to a different box format can be carried out very quickly and without involving any great expense outlay. For this purpose, the bearing part 57 , whereon the hold-down bar 54 with the imbricating finger 56 is fastened, and the bearing part 53 of the imbricating roller 51 are connected to one another via levers 58 , which are adjusted jointly by a handwheel 60 via an adjusting rod 59 . The lever mechanism formed by the bearing parts 53 , 57 and the levers 58 is configured so that the movements of the hold-down bar 54 , with the imbricating finger 56 , and of the imbricating roller 51 are coupled to the necessary extent, with the result that, in the case of a format adjustment, each part assumes the new position thereof. In order for the position of the imbricating roller 51 to be additionally adjustable in relative terms, this roller 51 is fastened so that it is additionally adjustable on the bearing part 53 thereof. The jointly coupled adjustment of the elements makes it possible to automate the adjustment. Instead of the handwheel 60 , use is then made of an adjusting drive, which moves the adjusting rod 59 .
[0049] The feeder or supply device 3 , which is illustrated in greater detail in FIG. 9, includes belts 4 as conveying elements, which extend into the accumulating section 55 , and thus also convey in the direction counter to the accumulating boxes 1 . They are advantageously configured so that the conveying action of the conveying belts 4 is dependent upon the bearing pressure of the boxes 1 , and this dependency can be adjusted in addition. For this purpose, each conveying belt 4 , as is illustrated in the sectional view of FIG. 10, is guided between two top guide bars 70 , and rests on a flexible pressure tube 71 which can be subjected to the action of compressed air. Disposed between the flexible pressure tube 71 and the conveying belt 4 is a thin, deformable plate 72 via which the conveying belt 4 can slide with low friction. The conveying belt 4 is guided between the guide rails 70 , in a manner supported by the flexible pressure tube 71 , so that, without being forced downwardly by the weight of the boxes 1 resting thereon, it projects beyond the top surfaces of the guide bars 70 . The belt 4 thus acts upon the undersides of the boxes 1 and conveys the latter further. If the weight of the boxes 1 increases, the conveying belt 4 is then forced downwardly counter to the force of the flexible pressure tube 71 . In this regard, it moves downwardly relative to the top surfaces of the guide rails 70 until the latter are located in a single plane with the top surface of the belt 4 . In this position, the boxes rest on the top surfaces of the rails 70 and are no longer conveyed further by the belt 4 . Depending upon the weight of the boxes 1 resting thereon, it is thus possible for a different conveying force to be established over the conveying length of the belts 4 . The conveying force is very low in the region of the accumulating section 55 , while it is high at the start of the feeder 3 because, thereat, the boxes 1 rest on the belts 4 in a condition wherein they are imbricated at a relatively great distance apart from one another. The change in the conveying action of the belts 4 in dependence upon the weight of the boxes 1 resting thereon can be adjusted via the pressure in the flexible pressure tube 71 . For this purpose, each flexible pressure tube 71 is connected to a compressed-air source 70 via lines 73 and a control valve 74 .
[0050] The two guide rails 70 and the flexible pressure tube 71 with the conveying belt 4 resting thereon, respectively, extend over the entire conveying section of the feeder 3 . For this purpose, they are disposed between two plate-like side parts 75 , which are screwed to one another and are mounted so that they are adjustable transversely on spindles 76 . The spindles 76 extend transversely to the conveying direction and are mounted, by the ends thereof, in side parts 77 of the framework of the feeder 3 . Two conveying belts 4 are preferably mounted in the aforedescribed manner, at a distance from one another, respectively, and so that they are adjustable transversely, individually, on spindles 76 , and are driven jointly via a tilting shaft 79 connected to a rotary drive 78 . The stop 6 , which is likewise mounted in a transversely adjustable manner, is illustrated partly in section in FIG. 9. The boxes 1 are aligned on the stop 6 if they are supplied to the conveying belts 4 at an angle of 90° thereto. | A device for packing flat articles in transport containers includes a feeder for feeding the flat articles in imbricated form and a conveyor disposed downstream of the feeder, in travel direction of the flat articles. The conveyor has an at least approximately vertically extending end for discharging the articles into the transport containers for filling the transport containers therewith at a filling location. Equipment for further conveying the transport containers at the filling location includes two lateral belt conveyors disposed at the filling location for moving the transport containers forward during the filling thereof with the articles. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to a building system.
BACKGROUND TO THE INVENTION
[0002] There are several known approaches to the construction of buildings such as houses. These approaches include the use of bricks and mortar, the use of pre-cast concrete panels and the construction of a frame for upon which cladding is affixed.
[0003] These approaches all require considerable work to be done at the site of the building. An alternative approach is construct a building at a location, and then transport the building to the site on which it is to be located. The logistics of this alternative approach are quite complex, and such an approach clearly limits the size and shape of the building able to utilise such a method.
[0004] Building constituents such as walls, floors, ceilings and roofs are generally constructed by erecting a supporting structure, and then mounting the constituent to the supporting structure. Such an approach requires the entire supporting structure of the constituent to be fixed in position before the constituent can be mounted.
[0005] Building constituents such as walls, floors, ceilings and roofs, along with their associated supporting structure, can be supplied to a building site as raw building materials or in a partially assembled form. Supplying the raw materials requires a great deal of specialised construction work to be undertaken at the site. Supplying the constituents in a partially assembled form can reduce this problem, however the partially assembled constituents are often bulky and difficult to transport.
[0006] The present invention attempts to overcome at least in part some of the aforementioned disadvantages of previous building methods.
SUMMARY OF THE INVENTION
[0007] In accordance with one aspect of the present invention there is provided a building constituent assembly comprising at least one covering member and at least one supporting structure, the supporting structure including a plurality of supporting members each having first and second side portions located adjacent a covering member, characterised in that the first side portion of a first supporting member is complementary in shape to the second side portion of a second supporting member such that the first and second supporting members can engage each other by the overlay of the first side portion of the first supporting member and the second side portion of the second supporting member, such engagement restraining relative movement of the first and second supporting members in at least one direction. Preferably, the first and second side portions are corrugated.
[0008] In accordance with a second aspect of the present invention, there is provided a wall panel comprising a supporting structure and at least one covering member, the supporting structure having at least one supporting member adjacent a covering member, characterised in that the supporting member has as first side portion extending beyond the covering member and a second side portion adjacent the covering member, a receiving area being defined between the second side portion and the covering member, wherein the first side portion of the supporting member of a first wall panel is receivable within the receiving area of a second wall panel, the first side portion being complementary in shape to the second side portion such that the first side portion of the first wall panel engages the second dies portion of the second wall panel, the engagement restraining relative movement of the first and second wall panels in at least one direction and the covering member restraining relative movement of the first and second wall panels in a second direction.
[0009] In accordance with a third aspect of the present invention there is provided a building constituent assembly comprising a supporting structure and at least one covering member, characterised in that the supporting structure includes at least one supporting member having as a trough portion which is substantially V-shaped in a transverse direction, the supporting member having first and second side portions on opposed sides of the trough portion, the first side portion of a first supporting member being complementary in shape to the second side portion of a second supporting member such that the first and second supporting members can engage each other by the overlay of the first side portion of the first supporting member and the second side portion of the second supporting member, such engagement restraining relative movement of the first and second supporting members in at least one direction. The building constituent assembly of the third aspect may be a flooring assembly, a ceiling assembly and/or a roofing assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0011] FIG. 1 is an exploded plan view of a wall panel in accordance with the present invention;
[0012] FIG. 2 is a plan view of the wall panel of FIG. 1 shown in an assembled configuration;
[0013] FIG. 3 is a plan view of two wall panels such as that in FIG. 2 , shown in a connected configuration;
[0014] FIG. 4 is a partially cut away perspective view of a supporting structure of the wall panel of FIG. 2 ;
[0015] FIG. 5 is a partially cut away perspective view of the wall panel of FIG. 2 ;
[0016] FIG. 6 is a perspective view of a supporting member of a flooring assembly in accordance with the present invention;
[0017] FIG. 6 a is a cross sectional view of the supporting member of FIG. 6 ;
[0018] FIG. 7 is an exploded view of a supporting structure of a flooring assembly in accordance with the present invention;
[0019] FIG. 8 is a perspective view of the supporting structure of FIG. 7 in an assembled configuration;
[0020] FIG. 9 is an upper perspective view of the supporting structure of FIG. 7 ;
[0021] FIG. 10 is an exploded side view of a flooring assembly in accordance with the present invention;
[0022] FIG. 11 is a side view of the flooring assembly of FIG. 10 in an assembled configuration;
[0023] FIG. 12 is an exploded side view of a ceiling assembly in accordance with the present invention;
[0024] FIG. 13 is a side view of the ceiling assembly of FIG. 12 in an assembled configuration;
[0025] FIG. 14 is an exploded side view of a roofing assembly in accordance with the present invention;
[0026] FIG. 15 is a side view of the roofing assembly of FIG. 14 in an assembled configuration;
[0027] FIG. 16 is an end view of the roofing assembly of FIG. 15 ; and
[0028] FIG. 17 is a partially cut away view of a building constructed of constituent assemblies in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] Referring FIGS. 1 to 5 , there is shown a building constituent assembly comprising a plurality of wall panels 10 . Each wall panel 10 comprises a supporting structure 12 and two covering members 14 . The covering members 14 are constructed from a suitable building cladding material such as cement sheeting. Each covering member 14 has a front end 16 and a rear end 18 .
[0030] The supporting structure 12 includes two supporting members 20 in the form of corrugated sheets 22 affixed to each covering member 14 . Each corrugated sheet 22 extends from a front end 24 beyond the front end 16 of the covering member 14 , to a bend 26 adjacent the rear end 18 . Each corrugated sheet 22 is bent at approximately 90° at the bend 26 , and extends from the bend 22 to a rear end 28 . The rear end 28 is displaced internally of the wall panel 10 .
[0031] In the embodiment of the drawings, each corrugated sheet 22 has 11.5 wave peaks or corrugations. These are arranged with two wave peaks extending beyond the front end 16 of the corresponding covering member 14 , and comprising a first side portion 30 of the supporting member 20 ; 8 wave peaks lying adjacent the covering member 14 ; and 1.5 peaks forming a transverse portion 32 extending inwardly of the rear end 18 of the covering member 14 .
[0032] Each corrugated sheet 22 is fixed to a corresponding covering member 14 by suitable means such as adhesive along the first six peaks closest to the front edge 16 of the covering member 14 . The two peaks adjacent the covering member 14 , which are closest to the rear edge 18 comprise a second side portion 34 of the supporting member 20 . These peaks 34 are not fixed to the covering member 14 . A receiving area 36 is thus defined between the second side portion 34 and the covering member 14 .
[0033] The wall panel 10 further includes a plurality of bracing members 38 . The bracing members 38 support the supporting members 20 in opposed parallel relationship. Each bracing member 38 has a front end 40 and a rear end 42 . The rear end 42 is at least partially complementary in shape to the portion of the corrugated sheet 22 between the bend 26 and the rear end 28 .
[0034] The supporting structure 12 of a wall panel 10 is formed by bringing the two supporting members 20 into the correct opposed relationship, with a plurality of bracing members located therebetween as shown in FIG. 4 . In the connected configuration, the transverse portions 32 of the two corrugated sheets 22 overlie one another, and the rear end 42 of the bracing members 38 . The covering members 14 are affixed externally of the supporting structure 12 , as shown in FIG. 5 .
[0035] When thus assembled, the wall panel 10 has a male end 44 from which the first side portions 30 of the supporting members 20 protrude, and a female end 46 defined by the second side portions 34 .
[0036] Successive wall panels 10 , 10 a are connected as shown in FIG. 3 .
[0037] The first side portions 30 of the supporting members 20 of wall panel 10 are received within the receiving areas 36 of wall panel 10 a , that is between the second side portions 34 and the covering members 14 . It will be appreciated that the corrugations of the first and second side portions 34 , 36 are complementary in shape, thus allowing each first side portion 34 to overlay a corresponding second side portion 36 .
[0038] When in the position shown in FIG. 3 , the first side portions 34 of wall panel 10 engage the second side portions 36 of wall panel 10 a , and thus prevent movement of the two wall panels 10 , 10 a relative to each other in a direction perpendicular to the corrugations. The covering members 14 prevent the disengagement of the first side portions 34 from the second side portions 36 in a direction perpendicular to the covering members 14 .
[0039] In a preferred embodiment of the wall panel 10 , an aperture 48 passes through the front and rear ends 40 , 42 of each bracing member 38 , and through corresponding locations in the transverse portions 32 of each supporting member 12 . Brace members 38 of one wall panel 10 can thus be connected to brace members 38 of an adjacent wall panel 10 a though bolts 50 or similar connection means.
[0040] In a further preferred embodiment of the invention, the covering members 14 are contained within upper and lower extruded channels 52 , 54 as seen in FIGS. 4 and 5 . Referring to FIGS. 6 to 11 , there is shown a building constituent assembly comprising a flooring assembly 60 . The flooring assembly 60 comprises a supporting structure 62 and a plurality of substantially planar covering members 64 .
[0041] The supporting structure 62 includes a plurality of supporting members 66 as shown in FIGS. 6 and 6 a . Each supporting member 66 is elongated, and extends between a first end 68 and a second end 70 . Each supporting member 66 is substantially V-shaped in cross section, that is in a transverse direction, with a trough portion 72 extending between the first end 68 and the second end 70 .
[0042] Each supporting member 66 has a first side portion 74 and a second side portion 76 . The first and second side portions 74 , 76 are on opposed sides of the trough portion 72 , and extend outwardly from the upper ends of the V-shape in a transverse direction.
[0043] The supporting members 66 are constructed from a corrugated material having waveforms oriented in the transverse direction. In the embodiment shown in the drawings, the first side portion 74 comprises one waveform, the second side portion 76 comprise one half of a wave form, and each of the side walls of the trough portion 72 comprise four and a half wave forms. A portion of the first side portion 74 is thus complementary in shape to the second side portion 76 .
[0044] The supporting structure 62 comprises supporting members 66 , secondary support members 78 and base members 80 . These elements can be seen in FIG. 7 .
[0045] The secondary support members 78 are preferably formed from a flat metal bar 82 which is bent along its length. The bar is bent to form a plurality of V-shaped sections 84 , joined at their upper ends by short horizontal portions 86 . The V-shaped sections 84 have a profile similar to that of the trough portion 72 of the supporting members 66 . The length of the horizontal portions 86 is similar to the width of the second side portion 76 of the supporting members 66 . In use, a plurality of supporting members 66 can be placed along the secondary support member 78 , with one supporting member 66 located within each V-shaped section 84 .
[0046] Each secondary support member 78 has a horizontal portion 86 a , 86 b at both outer ends thereof. The horizontal portion 86 b at a second end of a secondary support member 78 is slightly lower than other horizontal portions 86 , all of which are substantially co-planar. This allows a plurality of secondary support members 78 to be connected end to end, with a horizontal portion 86 a at one end of a first secondary support member 78 located above the horizontal portion 86 b at the other end of a second secondary support member 78 a.
[0047] It will be appreciated that the number of V-shaped sections 84 along each secondary support member 78 , and therefore the length of each secondary support member 78 , can be varied for particular applications.
[0048] The base members 80 are preferably formed from angle iron lengths having a first end 88 and a second end 90 . Each base member 80 has a depression formed at its second end 90 , to allow the endwise connection of a plurality of base members 80 whilst maintaining a substantially planar upper surface. Preferably, the base members 80 are similar in length to the secondary support members 78 .
[0049] A plurality of apertures 92 are located at appropriate points within the supporting members 66 , along the secondary support members 78 and in the base members 80 . These apertures allow the insertion of suitable fixing devices such as bolts or rivets to hold the secondary support members 78 to the base members 80 , and the supporting members 66 to the secondary support members 78 , thus forming the supporting structure 62 .
[0050] In use, the supporting members 66 are effectively tiled in both the elongate and transverse directions. In the transverse direction, adjacent supporting members 66 engage each other by overlay of the first side portion 74 of a first supporting member 66 a and the second side portion 76 of the second supporting member 66 b . In the elongate direction, adjacent supporting members 66 a , 66 c are arranged such that a portion of the length of a third supporting member 66 c is contiguous with, and overlaps, the first supporting member 66 a . The arrangement is such that the overlapping portion extends between, and is supported by, two parallel secondary support members 78 .
[0051] Secondary support members 78 and corresponding base members 80 are located beneath the supporting members 66 in a plurality of substantially parallel lines. The placement and number of the parallel lines can be determined by the requirements of a particular construction.
[0052] Preferably, the supporting members 66 are tiled in an offset pattern as shown in FIG. 3 .
[0053] It will be appreciated that the support structure 62 of the flooring assembly 60 can be constructed in a sequential fashion from an initial location. When the support structure 62 is to be located on supporting poles (not shown), it only becomes necessary to erect a supporting pole at a location when the support structure 62 reaches that location. In this way, a building can be constructed over irregular terrain without the need for extensive site preparation.
[0054] The flooring assembly 60 of the present invention is completed by the use of the substantially planar covering members 64 . The covering members 64 are comprised of flooring sheets 64 a . The completed flooring assembly is shown in FIGS. 10 and 11 .
[0055] Each flooring sheet 64 a is fixed to the supporting members 66 by suitable means such as a fastener passing through the side portions 74 , 76 of adjacent supporting members 66 and an associated secondary support member 78 . In this way the flooring sheet 64 a engages the supporting members 66 and acts to lock them in position relative to one another.
[0056] FIGS. 12 and 13 show a ceiling assembly 94 . The ceiling assembly 94 is substantially similar to the flooring assembly 60 , however is inverted with respect to the flooring assembly 60 . The ceiling assembly 94 has a support structure 62 similar to that of the flooring assembly 60 , and a plurality of covering members 64 comprised of ceiling sheets 64 b , such as cement sheeting.
[0057] In a preferred embodiment of the ceiling assembly 94 , each ceiling sheet 64 b corresponds to an associated supporting member 66 , and is sized so as to abut an adjacent ceiling sheet 64 b when the supporting members 66 are tiled as described herein above with respect to the flooring assembly 60 .
[0058] FIGS. 14 to 16 show a roofing assembly 96 . The roofing assembly 96 is substantially similar to the ceiling assembly 94 , with the covering members 64 comprising of an eves lining sheet 64 c . In the roofing assembly 96 the base member 80 is preferably a “Z” purlin 80 b , to which is attached corrugated roofing sheets 98 .
[0059] The roofing assembly 96 is erected in a manner similar to that of the ceiling assembly 94 , but is erected at a suitable pitch. Preferably, supporting struts 99 extend from the ceiling assembly 94 to support the roofing assembly 96 during construction.
[0060] FIG. 17 shows a building 100 having a flooring assembly 60 , wall panels 10 , a ceiling assembly 94 and a roofing assembly 96 all in accordance with the present invention.
[0061] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. | A building system is disclosed having building constituent assemblies including wall panels ( 10 ), a flooring assembly ( 60 ), a ceiling assembly ( 94 ) and a roofing assembly ( 96 ). Each of the building constituent assemblies includes a supporting structure ( 12, 62 ) and a covering member ( 14, 64 ). The supporting structure ( 12, 62 ) includes a supporting member ( 20, 66 ) which has a corrugated first side portion ( 30, 74 ) and second side portion ( 34, 76 ). The side portions of adjacent supporting structures ( 12, 62 ) overlay each other and interlock the adjacent constituent assemblies together. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to apparatus and methods for the wet processing of textile articles and, more particularly, to apparatus and methods for washing textile articles, e.g., before or after a dyeing operation.
[0002] It has been commonplace for centuries to subject textile articles to various wet processing treatments at varying stages of textile manufacturing operations. As one example, the vast majority of textile articles are dyed at some stage of their overall processing to impart coloration for aesthetic and style reasons. The types of apparatus and processes used for textile dyeing are numerous and diverse. Likewise, the dyes used for such operations are equally varied. Ancillary processes are also commonly carried out on textile articles before and/or after dyeing, e.g., textile articles may be subjected to a washing operation before dyeing to prepare the textile articles to receive dye and, likewise, textile articles may be washed after dyeing to remove excess dye.
[0003] Despite many modern advances in textile chemistry and, particularly, in the development of synthetic dyes and dyeing processes, many textile articles continue to be dyed using natural dyes applied by techniques which have been known and used for centuries. One particular example is the use of plant-derived indigo dyes used in the production of cotton-based denim fabrics. Due largely to the increasing popularity of wearing apparel made of denim, particularly so-called blue jeans, the use of indigo dyes continues to rise despite the relatively primitive nature of the dye and inefficiencies and environmental concerns with its use.
[0004] Indigo dyeing is predominantly performed on textile yarns, e.g., in the form of a traveling rope assembled of multiple individual yarns or in a traveling open sheet of side-by-side yarns, prior to their incorporation into denim fabric. Basically, the dyeing process requires the yarn rope or sheet to be passed into and out of multiple dip baths to progressively build penetration of the dye into the constituent yarns. Preparatory to dyeing, the yarns may be washed to remove impurities such as natural oils, waxes, and foreign matter which typically are found in natural cotton fibers. Likewise, after the yarn rope or sheet has undergone a sufficient number of dippings to achieve a desired dye shade, the yarns must then be washed through a series of water rinse baths to remove excess dye which remains on the yarn surfaces without having penetrated into the yarns.
[0005] Although machinery has been developed to automate these operations, this basic process of indigo dyeing has remained largely unchanged. Overall, the process presents many environmental concerns due to the substantial volumes of water which must be utilized for the numerous dip baths and for pre-dyeing and post-dyeing washings and, in turn, the substantial volumes of dye solution and dirty wash water which must be cleaned. In recent years, considerable effort has been devoted to developing advanced techniques for rehabilitating dye solutions and dirty wash water, but little effort has been successfully devoted to reducing the amount of water used in the first place.
[0006] Accordingly, a need exists within the textile industry for improved apparatus and processes used in the wet processing of textile articles, particular in association with textile dyeing operations, by which the amount of clean water devoted to the such wet processing operations can be reduced thereby lessening the required clean-up and attendant environmental impact.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the present invention to improve the apparatus and methods used for the washing of textile articles to lessen the amount of clean water or other cleansing liquid required. A more specific object of the present invention is to provide an improved apparatus and method for rinsing indigo-dyed yarn ropes or sheets using a substantially reduced volume of water as compared to known conventional rinsing operations. A further object of the present invention is that such improvements may find a broader applicability in other textile wet processing operations. Still further objects and benefits of the present invention will be apparent from the following disclosure of a preferred embodiment of the invention.
[0008] Briefly summarized, the present invention provides an apparatus for washing an elongate textile article of extended indeterminate length, and basically comprises a containment structure defining a channel extending upwardly from a lower end to an upper end thereof, with a plurality of undulations spaced-apart from one another within the channel between the lower and upper ends thereof, each undulation extending transversely across the channel. An arrangement is provided for guiding the elongate textile article to travel in its longitudinal extent with a portion of its lengthwise extent advancing transiently within the channel upwardly from the lower end to the upward end and across the undulations. A substantially continuous supply of a cleansing liquid, e.g., water, is delivered into the channel at the upper end for downward flow against the upwardly traveling portion of the textile article for cleansing thereof.
[0009] As noted, the apparatus is particularly adapted for rinsing indigo dyestuff from an elongate textile rope or sheet comprised of multiple textile yarns and containing an indigo dye partially penetrated into the yarns and partially residing on surfaces of the yarns from which rinsing of the indigo dye is required. However, the present invention is not intended to be so limited in its potential uses and application, but is believed to be equally applicable to other textile rinsing and/or washing operations for other types of textile articles.
[0010] In a preferred embodiment of the present apparatus, the channel may have a lateral dimension sufficient for a plurality of the elongate textile articles to travel alongside one another within the channel. According to another aspect of the invention, the containment structure preferably defines an open front to the channel for viewing of the rinsing action on the traveling textile article. The channel preferably extends at an inclined upward angle. More preferably, the containment structure may have an upwardly inclined bottom wall bordered by two lateral side walls which define the channel therebetween. The undulations may comprise transverse corrugations spaced along the bottom wall of the containment structure.
[0011] In a preferred embodiment, the arrangement for guiding the elongate textile article may comprise guide rollers adjacent the lower and upper ends of the channel and, more particularly, the guide rollers may comprise a pair of nip rollers disposed adjacent the upper end of the channel for squeezing excess rinse water or other cleansing liquid from the textile article after exiting the channel. Advantageously, the nip rollers may be disposed to redirect the squeezed rinse water or cleansing liquid into the channel.
[0012] Preferably, the supply of water or other cleansing liquid is adapted to flow gravitationally into and through the channel. For example, the supply of water or other cleansing liquid may comprise a weir disposed to overflow into the upper end of the channel. It is further preferred that a vessel is disposed adjacent the lower end of the channel for collecting rinse water or other cleansing liquid flowing from the lower end of the channel.
[0013] In a particularly advantageous installation of the present apparatus, a plurality of the apparatus may be arranged adjacent one another for travel of the textile article in sequence through the respective channels thereof. In such an installation, each apparatus may comprise a vessel disposed adjacent the lower end of its respective channel for collecting rinse water or other cleansing liquid and conduits may be provided to connect the vessels in sequence to provide for counterflow of the collected water or other cleansing liquid to the preceding apparatus.
[0014] According to another aspect of the present invention, a method is provided for washing an elongate textile article of extended indeterminate length. Briefly summarized, the method comprises the basic steps of guiding the elongate textile article to travel in its longitudinal extent with a portion of the lengthwise extent of the textile article advancing transiently within a channel along an upwardly inclined path and across a plurality of spaced-apart transverse undulations within the channel, while a substantially continuous supply of water or other cleansing liquid is delivered into an upper end of the channel for downward flow against the upwardly traveling portion of the textile article for cleansing thereof.
[0015] In a preferred embodiment of the method, excess rinse water or other cleansing liquid is squeezed from the textile article after exiting the channel. It is further preferred that the rinse water or other cleansing liquid be flowed gravitationally into and through the channel. The rinse water or other cleansing liquid is preferably collected at a lower end of the channel. In an advantageous installation, the guiding and delivering steps are repeated multiple times in sequence until the textile article achieves a desired cleanliness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings and the following description thereof are provided for illustrative purposes in describing one possible embodiment of the present invention, but without limitation on the overall scope, substance and broader applicability of the invention in other embodiments.
[0017] FIG. 1 is a schematic diagram depicting a conventional prior art form of dye range for the indigo dyeing and rinsing of textile yarn ropes;
[0018] FIG. 2 is a schematic diagram depicting an apparatus in accordance with a preferred embodiment of the present invention for rinsing indigo dye from textile yarn ropes; and
[0019] FIG. 3 is a photograph depicting a close-up image of the rinsing action achieved in the apparatus of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to the accompanying drawings and initially to FIG. 1 , a typical conventional form of textile dye range used for the indigo dyeing of textile yarn ropes is schematically depicted and basically comprises a creel section indicated generally at 10 , a dyeing section indicated generally at 12 , a washing/rinsing section indicated generally at 14 , a drying section indicated generally at 16 , and a coiling section indicated generally at 18 . The creel section 10 comprises a plurality of storage beams 11 from which a corresponding plurality of textile yarn ropes 20 are delivered via an overhead guide structure 22 to an entrance end of the dyeing section 12 . The dyeing section 16 comprises a series of vats 24 , each containing an indigo dye solution, with guide rollers 26 disposed above and within each vat 24 for directing the ropes 20 to travel into and out of the dye solution. A superstructure 26 , sometimes referred to in the industry as a “skying” section, is situated above the series of vats 24 and comprises a series of multiple guide rollers 30 by which the yarn ropes 20 are elevated out of each bath to allow for oxidation and penetration of the dye into the yarn ropes before immersion in the next following vat 24 . The number of vats 24 may vary depending on the depth of shade to be imparted to the yarn ropes 20 .
[0021] Following the dyeing section 12 , the yarn ropes are directed from the superstructure 28 into a series of rinse baths 32 in the washing/rinsing section 14 , each bath 32 being filled with a quantity of water within which the ropes 20 are guided via rollers 33 in a serpentine path to progressively rinse excess indigo dye from the ropes 20 . The number of rinse baths 32 may vary in relation to the number of dye vats 24 and, in turn, according to the amount of retained excess indigo dye required to be removed from the ropes 20 . Following the last rinse bath 32 , the ropes are directed to the drying section 16 wherein the ropes follow a serpentine path about a series of drying drums 34 and are then directed to the coiling station 18 at which each rope 20 is respectively directed to a coiler mechanism 36 which lays the rope 20 into a storage container 38 in a series of overlapping coils until the container is filled.
[0022] As previously indicated, one of the inefficiencies and environmental disadvantages of conventional indigo dye ranges of the type of FIG. 1 is the significant volume of water required in the washing/rinsing section 14 to sufficiently remove the excess indigo dye before the ropes 20 can be dried and coiled into the storage containers 38 for further processing. The present invention provides an alternative form of washing/rinsing section 114 , depicted in FIG. 2 , which can be substituted for the washing/rinsing section 14 in conventional dyeing ranges and which will perform an equally effective rinsing of excess dye using a substantially reduced volume of water.
[0023] With reference now to FIG. 2 , the washing/rinsing section 114 of the present invention comprises a series of rinsing apparatus 132 which do not rely upon or utilize a contained bath of rinse water. Each rinse apparatus 132 basically comprises an elongated angularly-upstanding rinsing containment structure 140 having a bottom wall 142 flanked by spaced-apart lateral side walls 144 collectively defining therewithin a channel 146 extending upwardly at an incline from a lower end 148 to an upper end 150 . Within the channel 146 , the bottom wall 142 is formed with a plurality of undulations 152 , preferably in the form of a series of angular corrugations projecting forwardly from the bottom wall 142 at spacings along the length of the channel 146 , each undulation 152 extending transversely across the channel 146 between the opposing side walls 144 .
[0024] Each rinsing apparatus 132 further includes a superstructure 154 situated directly above the containment structure 140 . The superstructure 154 supports a weir 156 disposed adjacent and directly above the upper end of the channel 146 and continuously fed with a flow of water from a water feed 158 to overflow into and flow gravitationally downwardly through the channel 146 . The superstructure 154 also supports a pair of nip rollers 160 spaced slightly above the weir 156 with the nip location between the rollers disposed directly above the upper end 150 of the channel 146 . The lower end of the containment structure 140 extends into a collection vessel 162 which includes a series of guide rollers 164 . The collection vessels 162 of the respective rinsing apparatus 132 are connected for water flow between each other by a series of conduits 166 .
[0025] The operation of the washing/rinsing section 114 of the present invention may thus be understood. As previously indicated, the washing/rinsing section 114 would be situated in place of the washing/rinsing section 14 in an otherwise conventional indigo dye range such as that shown in FIG. 1 . Thus, the washing/rinsing section 114 will receive one or more textile yarn ropes 20 , typically a plurality of such ropes, each of an elongate extended indeterminate length, traveling lengthwise in side-by-side slightly spaced-apart relationship as delivered from the dyeing section 12 . The incoming ropes 20 are directed into the first rinsing apparatus 132 and trained in serpentine fashion about the guide rollers 164 within its collection vessel 162 . From the last guide roller 164 , the ropes 20 are directed into the lower end 148 of the channel 146 and then upwardly through the full length of the channel 146 of the containment structure 140 to travel across and in contact with or at least close proximity to the series of undulations 152 , with the ropes 20 exiting the upper end 150 of the channel 146 and proceeding immediately into the nip between the nip rollers 160 .
[0026] As the ropes 20 progress in this path of travel, water from the weir 156 continuously counter flows gravitationally downwardly through the channel 146 against the upwardly moving ropes 20 to rinse the portion of the length of each rope 20 transiently advancing upwardly through the channel 146 . As the wetted ropes 20 pass between the nip rollers 160 , the ropes 20 are squeezed by the rollers 160 , causing the water squeezed from the ropes 20 to fall gravitationally into the upper end of the channel 146 . The collection vessel 162 collects the downward flow of water exiting the lower end 148 of the channel 146 and exhausts the collected water via an exhaust opening 170 . Following the nip rollers 160 , the ropes pass about another guide roller 168 and are directed downwardly therefrom into the collection vessel 162 and about the guide rollers 164 thereof within the next following rinsing apparatus 132 to undergo the same process.
[0027] The undulations 152 in the containment structure 140 contribute to the effectiveness of the rinsing apparatus 132 by periodically interrupting the gravitational flow of the rinse water and causing the rinse water to be diverted outwardly to penetrate into and through each rope 20 . FIG. 3 is a photograph taken of an actual demonstration prototype of the rinsing apparatus 132 during a non-production operation conducted for demonstrative developmental purposes and depicts the action of the gravitationally flowing rinse water at the location of one undulation 152 . This water action induced by the undulations 152 promotes more rapid rinsing of surface dye from the constituent yarns in the ropes 20 than can be achieved by merely passing the ropes 20 through a non-moving bath of water as in conventional dye ranges.
[0028] As will be readily recognized and understood by persons skilled in the industry, the volume of water required by each rinsing apparatus 132 to perform the ongoing rinsing operation will be substantially reduced in comparison to the volume of water required to be maintained within the rinse baths 32 in a conventional indigo dye range. Although empirical testing of the present apparatus and method in actual operation has not yet been performed, it is presently anticipated that the amount of required water may be reduced by about 30%, but actual results in a given embodiment of the invention could be greater or lesser. An additional feature of the present invention is that the rinse water collected in the collection vessel 162 of each rinsing apparatus 132 is exhausted via its exhaust opening 170 into the collection vessel 162 of the immediately preceding rinsing apparatus 132 from which the water may in part be directed to the weir 156 of such rinsing apparatus 132 , which further contributes to the overall water savings. The number of rinsing apparatus 132 required to make up a washing/rinsing section 114 in any given indigo dye range will depend upon various factors, including but not limited to the number of dyeing vats 24 making up the dyeing section 12 , but it is anticipated that the number of rinsing apparatus 132 would be no greater than and potentially less than the number of rinse baths 32 conventionally required.
[0029] An additional advantage of the present washing/rinsing section 114 is that the channel 146 is open at the forwardly facing side of each containment structure 140 , which enables operational personnel to visually inspect the clarity of or, alternatively, the dye coloration in the rinse water flowing through each channel 146 in each rinsing apparatus 132 so as to monitor the effectiveness of the rinsing operation. In turn, adjustments may be made in operational parameters, such as water flow rate, etc., as necessary to achieve the desired degree of rinsing of the ropes using the least amount of water required.
[0030] It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | Apparatus and method for washing an elongate textile article of extended indeterminate length utilizes a containment structure defining a channel extending upwardly from a lower end to an upper end thereof, with a plurality of undulations spaced-apart from one another within the channel between the lower and upper ends thereof, each undulation extending transversely across the channel. A portion of the lengthwise extent of the traveling textile article is advanced transiently within the channel upwardly from the lower end to the upward end and across the undulations, while a substantially continuous supply of cleansing liquid enters the channel at the upper end to flow downwardly against the upwardly traveling portion of the textile article for cleansing thereof. | 3 |
BACKGROUND OF THE INVENTION
A wiper device, particularly a motor vehicle windscreen wiper device, having a wiper blade adapter is already known in the art.
SUMMARY OF THE INVENTION
The invention is based on a wiper device, particularly a motor vehicle windscreen wiper device, having a wiper blade adapter.
It is proposed that the wiper blade adapter comprises a pivot bearing which is provided to pivotably support a spring element, as a result of which the spring element can be particularly flexibly configured and a contact pressure on a surface to be wiped can be distributed particularly evenly. A “wiper blade adapter” in this context should be particularly understood to mean an adapter which exhibits a contact area to a wiper blade component and is connected to the wiper blade component in an undetachable manner and is provided to supply a connection area of the wiper blade component for a connection and/or contact with a wiper arm adapter. A “pivot bearing” in this context should be particularly understood to mean a bearing which is provided to connect two components to one another, so as to allow a pivoting movement about a pivot axis. A “spring element” in this context should be particularly understood to mean a resilient element which comprises at least one extension, said extension being elastically variable in a normal operating state by at least 10%, particularly by at least 20%, preferably by at least 30%, and particularly advantageously by at least 50%, and which particularly generates a counterforce which depends on a change in the extension and is preferably proportionate to the change, said counterforce acting against the change. “Pivotable” in this context should be particularly understood to mean deflectable within a large part of the wiper blade adapter. A “large part” in this context should be particularly understood to mean more than 50%. “Deflectable” in this context should be particularly understood to mean movable to one another. “Provided” should be particularly understood to mean specially designed and/or equipped.
In a further embodiment of the invention, it is proposed that the pivot bearing has at least one punctiform and/or linear bearing surface, which is provided to support the spring element in a mounted state. “Punctiform and/or linear” in this context should be particularly understood to mean less than 10%, preferably less than 5%, particularly preferably less than 1%, of a total longitudinal extension of the wiper blade adapter, at least viewed in a longitudinal direction of the wiper blade adapter. A “bearing surface” in this context should be particularly understood to mean a surface at which a spring element in a mounted state at a particular point in time bears against the wiper blade adapter. A “longitudinal direction” in this context should be particularly understood to mean a direction which extends substantially parallel to a longitudinal extension of the wiper blade adapter. A “longitudinal extension” in this context should be particularly understood to mean a largest possible extension. “Substantially” in this context should be particularly understood to mean a deviation of less than 10°, preferably less than 5°. An “extension” of an element in this context should be particularly understood to mean a maximum distance between two points on a perpendicular projection of the element on a plane.
It is further proposed that the wiper blade adapter comprises at least one free space which is provided to space the spring element at least over a large part of a longitudinal extension of the wiper blade adapter from said wiper blade adapter in a vertical direction, by virtue of which a deflection of the spring element can be achieved particularly simply.
Furthermore, it is proposed that the at least one bearing surface is arranged centrally in the wiper blade adapter, viewed in a longitudinal direction. “Centrally” in this context should be particularly understood to mean an area which is arranged in between 45% and 55% of the total longitudinal extension.
If the pivot bearing exhibits at least a first and a second punctiform and/or linear bearing surface, which is provided to support the spring element in a mounted state, a particularly rigid connection between the wiper blade adapter and the spring element can be achieved.
In a further embodiment of the invention it is proposed that the wiper device exhibits a retaining element, which is provided to connect the spring element to a wiper strip and to a wind deflector element in a mounted state. A “retaining element” in this context should be particularly understood to mean an element which is provided to connect a wind deflector element, a spring element and a wiper strip in an interlocking manner. A “wiper strip” in this context should be particularly understood to mean a strip which is provided to wipe a vehicle windscreen. A “wind deflector element” in this context should be particularly understood to mean an element which is provided to deflect a headwind acting on the wiper device and/or to use it to press a wiper strip against a vehicle windscreen.
A particularly rigid connection can be achieved between the retaining element and the wiper blade adapter when the retaining element has at least one fastening recess, which is provided to receive the wiper blade adapter in an interlocking manner in a mounted state. A “fastening recess” in this context should be particularly understood to mean a recess which is provided to receive a corresponding fastening element.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages emerge from the following drawing description. Two exemplary embodiments of the invention are depicted in the drawing. The drawings, description and claims contain a plurality of combined features. The person skilled in the art will advantageously observe the features individually too and bring them together to create further appropriate combinations.
In the figures:
FIG. 1 shows a perspective view of a wiper device according to the invention with a wiper blade adapter and a retaining element,
FIG. 2 shows a sectional view of the retaining element according to FIG. 1 ,
FIG. 3 shows a top view of the retaining element according to FIG. 1 ,
FIG. 4 shows a further perspective view of the wiper blade adapter and the retaining element according to FIG. 1 ,
FIG. 5 shows a perspective view of a section through the wiper blade adapter according to FIG. 1 and through a spring element,
FIG. 6 shows a top view of a retaining element of a further exemplary embodiment of a wiper device according to the invention,
FIG. 7 shows a bottom view of the retaining element according to FIG. 6 with a wiper blade adapter and
FIG. 8 shows a sectional view of a spring element and the wiper blade adapter according to FIG. 7 .
DETAILED DESCRIPTION
FIG. 1 shows a perspective view of a wiper device according to the invention with a retaining element 10 a , a wiper blade adapter 12 a , a wind deflector element 14 a and a wiper strip 16 a in a mounted state. The wiper blade adapter 12 a , the wind deflector element 14 a and the wiper strip 16 a are fastened to the retaining element 10 a . The wiper blade adapter 12 a is provided to be connected to a wiper arm (not shown). In an operating state, i.e. when the wiper arm executes a wiper movement, the wiper strip 16 a is moved via the retaining element 10 a over a surface to be wiped (not shown). When a headwind is encountered, the wind deflector element 14 a deflects this and presses the wiper device onto the surface to be wiped.
FIG. 2 shows the retaining element 10 a , which comprises a longitudinal guide channel 18 a to guide a spring element 20 a , as a sectional view. The sectional plane runs perpendicularly to a longitudinal direction 22 a of the retaining element 10 a . The retaining element 10 a has two wind deflector fastening elements 50 a , 52 a . The wind deflector fastening elements 50 a , 52 a are formed integrally with the retaining element 10 a . The wind deflector fastening elements 50 a , 52 a point at their free ends 54 a , 56 a in directions facing away from one another. In addition, the wind deflector fastening elements 50 a , 52 a form two channel walls 58 a , 60 a which bear against the longitudinal guide channel 18 a on a side facing away from the wiper strip. The wind deflector fastening elements 50 a , 52 a are barb-shaped in design in the region of their free ends 54 a , 56 a . The ends 54 a , 56 a are enclosed by the wind deflector element 14 a in a mounted state.
To guide the spring element 20 a , side walls 66 a , 68 a of the longitudinal guide channel 18 c bear against the channel walls 58 a , 60 a . The channel walls 58 a , 60 a thereby enclose a right angle with the side walls 66 a , 68 a . In addition, a partition wall 70 a is arranged at the side walls 66 a , 68 a , which closes the longitudinal guide channel 18 a in the direction of the wiper strip 16 a . The side walls 66 a , 68 a extend from the partition wall 70 a in a direction facing away from the wiper strip 16 a . The retaining element 10 a has a longitudinal opening 72 a , which opens the longitudinal guide channel 16 a towards the wind deflector element 14 a.
Two L-shaped guide profiles 74 a , 76 a of the retaining element 10 a are arranged on the partition wall 70 a . The guide profiles 74 a , 76 a are formed integrally with the retaining element 10 a . The guide profiles 74 a , 76 a each have a lateral guide 78 a , 80 a and a vertical guide 82 a , 84 a . The vertical guides 82 a , 84 a each enclose an angle of 90° with the lateral guides 78 a , 80 a . The lateral guides 78 a , 80 a each enclose an angle of 90° relative to the partition wall 70 a . The guide profiles 74 a , 76 a point at their ends free of the vertical guides 82 a , 84 a in directions facing one another. The guide profiles 74 a , 76 a and the partition wall 70 a form a welt track 86 a , into which the wiper strip 16 a is inserted in a mounted state.
The retaining element 10 a is produced integrally from polyethylene by an extrusion process. A person skilled in the art will consider different plastics which seem appropriate in this context, such as polypropylene, polyamide, polyvinyl chloride, polycarbonate and/or polystyrene in particular.
FIG. 3 shows a top view of the retaining element 10 a . The retaining element 10 a has two fastening recesses 32 a , 34 a , which are provided to receive the wiper blade adapter 12 a in an interlocking manner. The fastening recesses 32 a , 34 a are arranged in side walls 66 a , 68 a , which laterally delimit a longitudinal guide channel 18 a.
In one assembly, the wiper blade adapter 12 a is initially positioned on the retaining element 10 a in a vertical direction ( FIG. 4 ). The vertical direction 44 a extends perpendicularly to the longitudinal direction 22 a and perpendicularly to a wiping direction 24 a . The vertical direction 44 a is therefore perpendicular to a wiping surface (not shown) in an operating state.
The wiper blade adapter 12 a comprises a pivot bearing 26 a which pivotably supports the spring element 20 a ( FIG. 5 ). The pivot bearing 26 a has a punctiform bearing surface 28 a , which supports the spring element 20 a in a mounted state. The wiper blade adapter 12 a further comprises a free space 40 a , 42 a , which spaces the spring element 20 a apart over a large part of a longitudinal extension of the wiper blade adapter 12 a from said wiper blade adapter in the vertical direction 44 a . The bearing surface 28 a is arranged centrally in the wiper blade adapter 12 a , viewed in a longitudinal direction 22 a . A further identical pivot bearing is arranged symmetrically to the sectional plane for the pivot bearing 26 a , but is not shown for the sake of clarity.
The fastening recesses 32 a , 34 a extend in a mounted state in the area of the free space 40 a , 42 a and of the pivot bearing 26 a.
The retaining element 10 a can thereby be deflected within the wiper blade adapter 12 a in a vertical direction 44 a . A movement of the wiper blade adapter 12 a relative to the retaining element 10 a in a longitudinal direction 22 a and in the wiping direction 24 a is, however, avoided.
A further exemplary embodiment of the invention is shown in FIGS. 6 to 8 . The following descriptions are substantially limited to the differences between the exemplary embodiments, wherein reference can be made to the description of the first exemplary embodiment in relation to unchanging components, features and functions. To distinguish between the exemplary embodiments, letter a in the reference numbers in the exemplary embodiment in FIGS. 1 to 5 is replaced with the letter b in the reference numbers in the exemplary embodiment in FIGS. 6 to 8 . In relation to components with the same name, particularly in relation to components with the same reference number, reference can also be made in principle to the drawings and/or the description of the first exemplary embodiment.
FIG. 6 shows a retaining element 10 b of a further exemplary embodiment of a wiper device. A configuration of the retaining element 10 b corresponds in cross-section to the retaining element 10 a shown in FIG. 2 . The retaining element 10 b has four fastening recesses 32 b , 34 b , 36 b , 38 b which are arranged in side walls 66 b , 68 b . Two of the fastening recesses 32 b , 36 b , or 34 b , 38 b are arranged in each side wall 66 b , 68 b . The fastening recesses 32 b , 34 b , 36 b , 38 b have a trapezoidal outline.
A first assembly stage of the wiper device is shown in FIG. 7 . A wiper blade adapter 12 b is positioned on the retaining element 10 b and engages with the fastening recesses 32 b , 34 b , 36 b , 38 b in an interlocking manner. A movement of the wiper blade adapter 12 b relative to the retaining element 10 b in the longitudinal direction 22 b and in the wiping direction 24 b is avoided. A spring element 20 b is subsequently inserted into the retaining element 10 b . The wiper blade adapter 12 b comprises a pivot bearing 26 b . The spring element 20 b is supported in this case by a first and a second linear bearing surface 28 b , 30 b of the pivot bearing 26 b of the wiper blade adapter 12 b ( FIG. 8 ). For the sake of clarity, the retaining element 10 b is not shown in FIG. 8 . The wiper blade adapter 12 b comprises a free space 40 b , 42 b , which spaces the spring element 20 b over a large part of a longitudinal extension of the wiper blade adapter 12 b from said wiper blade adapter in a vertical direction 44 b . The spring element 20 b can thereby be deflected within the wiper blade adapter 12 b in a vertical direction 44 b . A further, identical pivot bearing is arranged symmetrically to the sectional plane for the pivot bearing 26 b , but is not shown for the sake of clarity. | The invention relates to a wiping device, in particular a wiping device for a motor vehicle pane, comprising a wiper blade adapter ( 12 a; 12 b ). According to the invention, the wiper blade adapter ( 12 a; 12 b ) comprises a pivot bearing ( 26 a; 26 b ) that is designed to pivotally mount a spring element ( 20 a; 20 b ). | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/558,695 filed Nov. 11, 2011, which is hereby incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of localization and mapping.
BACKGROUND OF THE INVENTION
[0003] The widespread deployment of wireless networks presents an opportunity for localization and mapping using signal-strength measurements. Wireless networks are ubiquitous, whether in the home, office, shopping malls, or airports.
[0004] Recent work in signal-strength-based simultaneous localization and mapping (SLAM) uses Gaussian process latent variable models (GP-LVM). This work, however, requires that maps are limited to very specific predefined shapes (e.g. narrow and straight hallways) and WiFi fingerprints are assumed unique at distinct locations. Generally, in the absence of any odometry information, arbitrary assumptions must be made about human walking patterns and data association.
[0005] GraphSLAM is a technique used in the robotics community for simultaneously estimating a trajectory and building a map offline. It shares many benefits of Gaussian processes, but can be applied to a broader range of environments. Below, it is shown how wireless signal strength SLAM can be formulated as a GraphSLAM problem. By using GraphSLAM, limitations of traditional approaches are addressed to improve runtime complexity from O(N 3 ) to O(N 2 ), where N is the dimensionality of the state space, i.e., the number of poses being estimated.
[0006] In both GraphSLAM and Gaussian processes, measurement likelihoods are modeled as Gaussian random variables. Gaussian processes can improve their model fit by moving points away from each other. To prevent these trivial solutions, GP-LVM methods require special constraints. In the case of signal strength SLAM, the special constraints force similar signal strengths to similar locations. GraphSLAM requires no special constraints. This makes GraphSLAM suitable to a wider range of real-world environments.
[0007] An appeal of GraphSLAM is that it reduces to a standard non-linear least squares problem. This gives GraphSLAM access to widely used and well-studied techniques for its optimization. A parameterization of the state space for typical mobile phone applications is presented below.
[0008] If wireless signal strength maps are determined ahead of time, Monte Carlo localization methods can achieve high accuracy indoor localization. In a traditional approach, the signal strength map is discretized into a spatial grid and, combined with contact sensing, obtains 0.25 m accuracy using standard Monte Carlo methods while improving convergence time over contact sensing alone. In another approach, spatial discretization of the signal strength map is performed and combine with WiFi with a low-cost image sensor to localize within 3 m. In traditional approaches, however, the process for obtaining signal strength maps is expensive and time consuming.
[0009] Outdoor applications have been handled by GPS and/or attenuation model or range-based SLAM methods. Other indoor signal-strength-based localization research relies on extensive training phases or incorporates other features of the signal such as time-of-arrival or angle-of-arrival measurements. In most pedestrian applications, however, such data is inaccessible to the general public without additional infrastructure costs. The implications of low-cost signal-strength SLAM are especially meaningful for large (indoor) GPS deprived environments such as shopping malls, airports, etc. where wireless internet infrastructure is readily accessible.
[0010] Existing wireless mapping techniques model the signal data in different ways. Some traditional techniques assume a model of the signal propagation. Others use a connectivity graph of predetermined cells to localize coarsely. Since these techniques rely on pre-existing information about the environment, they do not handle the problem of mapping in unknown locations.
[0011] The current state of the art uses Gaussian processes to determine a map of signal strength without modeling the propagation from transmitting nodes explicitly. Gaussian processes are applied to WiFi-SLAM under a specific set of assumptions.
SUMMARY OF THE INVENTION
[0012] The widespread deployment of wireless networks presents an opportunity for localization and mapping using only signal-strength measurements. The current state of the art is to use Gaussian process latent variable models (GP-LVM). This method relies on a signature uniqueness assumption which limits its applicability to only signal-rich environments. Moreover, it does not scale computationally to large sets of data, requiring O(N 3 ) operations per iteration.
[0013] In an embodiment of the present invention, a GraphSLAM-like algorithm for signal strength SLAM is presented. This algorithm shares many of the benefits of Gaussian processes, yet is viable for a broader range of environments since it makes no signature uniqueness assumptions. It is also more tractable to larger map sizes, requiring O(N 2 ) operations per iteration. Below, this algorithm is compared to a laser-SLAM ground truth, showing that it produces excellent results in practice.
[0014] In an embodiment of the present invention, the restriction that similar signal strength fingerprints/signatures all correspond to a similar location on the map is lifted. If the geographic distribution of access points is sparse, there are more spatial configurations where the fingerprint uniqueness assumption breaks down. As illustrated in FIGS. 1A and 1B , real-world hypotheses are often multi-modal.
[0015] Shown in FIGS. 1A and 1B are two examples 100 and 150 , respectively, of wireless node deployment. In each example, location A ( 102 and 152 , respectively) and location B ( 104 and 154 , respectively) share the same signal strength signature/fingerprint. But the configuration of the buildings 110 and 164 are different. For example, note spaces 112 and 164 in FIGS. 1A and 1B , respectively, as well as the locations of signal sources 106 , 108 , and 114 in FIG. 1A and signal sources 156 and 158 in FIG. 1B . More generally, at indoor scales, signal strength can often be relatively invariant over long regions of open areas in line-of-sight directions. Especially at lower signal strengths, due to the log relationship between signal strength and distance, signal strength can be almost completely invariant over very large sections of space.
[0016] Relaxing this requirement brings modern signal-strength-based SLAM to sparse signal environments. Furthermore, explicitly mapping similar signal strengths to similar locations hurts scalability: as the dataset grows, the risk increases of erroneous measurements being incorrectly mapped by this constraint. Since such mappings are hard constraints, these errors are completely unrecoverable. The current state of the art cannot achieve signal-strength SLAM without relying upon explicit fingerprint uniqueness back-constraints. In a traditional approach, the GP-LVM method is only reasonable in dense environments. The method of an embodiment of the present invention does not make any assumptions of fingerprint uniqueness. Therefore, signal density or sparsity, which influences fingerprint uniqueness, is not a concern in an embodiment of the present invention.
[0017] In order to provide a SLAM solution suitable for both rectilinear corridor-type environments as well as open atrium-type environments, in an embodiment of the present invention, low-cost IMU data is incorporated. Introducing motion measurements makes the sensor model general enough to apply to a wide range of crowd sourcing applications. In this embodiment, subjects need not explicitly cooperate with predetermined walking patterns, consistent walking speeds, etc. Motion sensors may also make the problem easier. The viability of low-cost WiFi SLAM according to an embodiment of the present invention is demonstrated below and compared to a laser-SLAM implementation.
[0018] In an embodiment, the scalability of modern signal strength SLAM is improved for larger datasets. In this embodiment, the proposed GraphSLAM based method is shown to have better runtime complexity than Gaussian process latent variable models. This method is demonstrated to produce useful results on real-world data.
[0019] Our results compare the GraphSLAM approach for WiFi SLAM against a LIDAR-based GraphSLAM implementation. Using real-world datasets, a localization accuracy of between 1.75 m and 2.18 m over an area of 600 square meters is demonstrated. The manner in which the resultant maps are directly applicable to online Monte Carlo Localization is discussed below.
[0020] These and other embodiments can be more fully appreciated upon an understanding of the detailed description of the invention as disclosed below in conjunction with the attached figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The following drawings will be used to more fully describe embodiments of the present invention.
[0022] FIGS. 1A and 1B are illustrations of deployments of wireless nodes.
[0023] FIGS. 2A and 2B are sample plots of h WiFi , Gaussian weighted interpolation of WiFi points, evaluated over a grid with scale parameter τ=2.2 m, according to an embodiment of the present invention.
[0024] FIGS. 3A-3C are graphs that compare GraphSLAM initialization and resulting optimized GraphSLAM posterior as well as the unaligned ground truth trajectory is provided for reference.
[0025] FIGS. 4A and 4B are graphs that shown the mean and standard deviation of the localization error according to an embodiment of the present invention.
[0026] FIG. 5 is a block diagram of a computer system on which embodiments of the present invention can be implemented.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Among other things, the present invention relates to methods, techniques, and algorithms that are intended to be implemented in a digital computer system 100 such as generally shown in FIG. 5 . Such a digital computer is well-known in the art and may include the following.
[0028] Computer system 500 may include at least one central processing unit 502 but may include many processors or processing cores. Computer system 500 may further include memory 504 in different forms such as RAM, ROM, hard disk, optical drives, and removable drives that may further include drive controllers and other hardware. Auxiliary storage 512 may also be include that can be similar to memory 504 but may be more remotely incorporated such as in a distributed computer system with distributed memory capabilities.
[0029] Computer system 500 may further include at least one output device 508 such as a display unit, video hardware, or other peripherals (e.g., printer). At least one input device 506 may also be included in computer system 500 that may include a pointing device (e.g., mouse), a text input device (e.g., keyboard), or touch screen.
[0030] Communications interfaces 514 also form an important aspect of computer system 500 especially where computer system 500 is deployed as a distributed computer system. Computer interfaces 514 may include LAN network adapters, WAN network adapters, wireless interfaces, Bluetooth interfaces, modems and other networking interfaces as currently available and as may be developed in the future.
[0031] Computer system 500 may further include other components 516 that may be generally available components as well as specially developed components for implementation of the present invention. Importantly, computer system 500 incorporates various data buses 516 that are intended to allow for communication of the various components of computer system 500 . Data buses 516 include, for example, input/output buses and bus controllers.
[0032] Indeed, the present invention is not limited to computer system 500 as known at the time of the invention. Instead, the present invention is intended to be deployed in future computer systems with more advanced technology that can make use of all aspects of the present invention. It is expected that computer technology will continue to advance but one of ordinary skill in the art will be able to take the present disclosure and implement the described teachings on the more advanced computers or other digital devices such as mobile telephones or smart televisions as they become available. Moreover, the present invention may be implemented on one or more distributed computers. Still further, the present invention may be implemented in various types of software languages including C, C++, and others. Also, one of ordinary skill in the art is familiar with compiling software source code into executable software that may be stored in various forms and in various media (e.g., magnetic, optical, solid state, etc.). One of ordinary skill in the art is familiar with the use of computers and software languages and, with an understanding of the present disclosure, will be able to implement the present teachings for use on a wide variety of computers.
[0033] For example, embodiments of the present invention can be implemented in cellular telephones including smart telephones that include the necessary computing and communications capabilities. Also, embodiments of the present invention can be implemented in tablet computers with the necessary hardware and software capabilities. More broadly, embodiments of the present invention can be implemented in general purposes devices with the necessary capabilities as described herein. Still other embodiments of the present invention can be implemented in stand-alone devices that are especially configured to implement the teachings of the present invention.
[0034] The present disclosure provides a detailed explanation of the present invention with detailed explanations that allow one of ordinary skill in the art to implement the present invention into a computerized method. Certain of these and other details are not included in the present disclosure so as not to detract from the teachings presented herein but it is understood that one of ordinary skill in the at would be familiar with such details.
Traditional GraphSLAM
[0035] The GraphSLAM family of techniques are used in the robotics community for simultaneously estimating a trajectory and building a map offline. Such techniques have been used in applications in computer vision and robotics. The signal strength SLAM problem is reduced to an instance of GraphSLAM as discussed below.
[0036] GraphSLAM is traditionally formulated as a network of Gaussian constraints between robot poses and landmarks. Measurements are assumed to contain only additive Gaussian noise and to be conditionally independent given the world states. For each measurement Z i from any sensor, a state-to-measurement mapping function h i (X) describes the true measurement that would have taken place if the value of the state variables were known:
[0000] Z i =h i ( X )+ε i
[0000] where
[0000] X={{right arrow over (x)} i 1 , {right arrow over (x)} i 2 , . . . , {right arrow over (m)} 1 , {right arrow over (m)} 2 , . . . }
[0000] represents the collection of all state variables (e.g. robot locations {{right arrow over (x)} i } and landmark locations {{right arrow over (m)} i }). The measurement likelihood as a function of z i is Gaussian with mean h i (X) and variance Var{ε i }.
Motion Model
[0037] The typical GraphSLAM motion model can be expressed as state-to-measurement mappings. For example, a pedometry measurement on the interval between time t i and t i+1 is related to the state space by the function
[0000] h i pedometry ( X )=∥ {right arrow over (x)} t i+1 −{right arrow over (x)} t i ∥ 2
[0038] Similarly, angular velocity measurements correspond to
[0000]
h
i
gyro
(
X
)
=
atan
2
(
x
→
t
i
+
1
-
x
→
t
i
)
-
atan
2
(
x
→
t
i
-
x
→
t
i
-
1
)
Δ
t
[0000] where Δt=(t i+1 −t i−1 )/2. Note that implementations must be careful to account for headings that cross over from −π to +π and vice versa.
[0039] The definition of a state-to-measurement mapping h together with the variance of the corresponding sensors noise, σ ε =Var(ε), describes the GraphSLAM measurement likelihood function for each sensor. The methods presented herein as embodiments of the present invention will work with any class of sensors. Pedometry and gyroscopes are merely used as examples here because they are the sensors of the sample dataset as discussed below.
WIFI Graphslam
[0040] The state-to-measurement mapping for the i th signal strength measurement is defined to be
[0000] h i WiFi ( X )={right arrow over (β)} i T {right arrow over (z)} WiFi
[0000] {right arrow over (β)} i ={right arrow over (ω)} i −[{right arrow over (ω)} i ] i {right arrow over (ε)} i , ∥{right arrow over (β)} i ∥ 1 =1
[0000] For notational convenience, {right arrow over (z)} WiFi is the vector of all signal strength measurements. {right arrow over (β)} i excludes the i th element from {right arrow over (ω)} i . {right arrow over (ω)} i is the vector of interpolation weights for h WiFi . The notation [{right arrow over (α)}] i is shorthand for the i th element of the vector {right arrow over (α)}, and {right arrow over (β)} i is the unit vector with all elements zero except the i th element. Note that h i does not interpolate the i th measurement. This allows the measurement model to operate in sparse WiFi environments.
[0041] At most distances from a transmission node, propagating radio waves are expected to have nearly the same power within any small region of free space. Over larger regions across non-free space the relationship between nearby signal strengths is highly dependent on building structure/architecture. Without a model for building structure, a method according to an embodiment of the present invention interpolates over small regions likely to be free space.
[0042] The quantity [{right arrow over (ω)} i ] i can considered as related to the probability that location i and location j are inter-polatable, e.g., nearby and separated by only free space. In practice, at reasonable scales and in lieu of additional knowledge, Gaussian interpolation weights are a popular kernel choice and have been used with success to interpolate WiFi signal strengths as well as in other machine learning applications.
[0000]
[
w
→
i
]
j
∝
exp
(
-
1
2
τ
2
x
→
t
i
-
x
→
t
j
2
2
)
[0000] where τ is a scale parameter, related roughly to the distance between walls (e.g., 95% of walls can be considered at least 2τ away from measurement locations). In an embodiment, τ can be learned from training data (the experimental value of τ for our dataset was approximately 2.2 meters). FIGS. 2A and 2B illustrate typical behavior of this signal interpolation method. More particularly, FIGS. 2A and 2B are sample plots 200 and 202 , respectively, of h WiFi , Gaussian weighted interpolation of WiFi points, evaluated over a grid with scale parameter τ=2.2 m, according to an embodiment of the present invention. As shown, black circles denote measured values. The vertical axis represents signal strength (dBm) and the horizontal axes represent spatial location.
[0043] With this formulation, for any specific measured value z i , the following is evaluated:
[0000]
z
i
-
h
i
(
X
)
=
ɛ
i
⇒
{
E
[
z
→
i
WiFi
-
∑
j
[
β
→
i
]
j
z
j
WiFi
]
=
0
Var
(
ɛ
i
WiFi
+
h
i
WiFi
(
X
)
)
=
(
1
+
β
→
i
2
2
)
Var
(
ɛ
WiFi
)
[0000] The WiFi measurement likelihood, as a function of z i , is Gaussian with mean h i (X) and variance
[0000] (1+∥{right arrow over (β)} i ∥ 2 2 )σ ε 2 .
[0000] where
[0000] σ ε 2 =Var(ε WiFi )
[0000] denotes the measurement noise variance associated with the WiFi sensor. In practice,
[0000] ∥{right arrow over (β)} i ∥ 2 2 <<1
[0000] for any sufficiently dense dataset (recall that ∥{right arrow over (β)} i ∥ 1 =1).
[0044] Observe that this formulation is free of any restrictions on fingerprint uniqueness, and is equally applicable to both sparse and dense signal environments.
[0045] Embodiments of the present invention can be implemented using hand-held devices such as cellular telephones, sometimes called smart-phones, tablet computers, or other computing devices having signal receivers such as WiFi transceivers. In such embodiments, the described algorithms can be implemented on the hand-held device itself or can be implemented on another computing device that is in communication with the hand-held device. Likewise, the collection of signal information can be performed on the handheld device itself or by other devices. Still other embodiments may distribute certain computational steps between a hand-held device and a separately networked computer. Computer networks in such cases can include cellular networks. Many other embodiments are possible as would be known to those of ordinary skill in the art upon understanding the teachings of the present disclosure.
Relationship to Gaussian Processes
[0046] Here, a few key differences between our measurement model according to an embodiment of the present invention and Gaussian processes are discussed. In Gaussian processes, the model fit to the WiFi measurements, as a function of z i , has mean:
[0000] h i GP ( X )= {right arrow over (k)} i T ( K+σ ε 2 I ) −1 {right arrow over (z)} WiFi
[0000] h i WiFi ( X )={right arrow over (β)} i T {right arrow over (z)} WiFi
[0000] σ ε 2 is measurement noise variance associated with the WiFi sensor. k i and K come from the choice of kernel weighting function.
[0047] The comparison to GraphSLAM is most clear when
[0000] [{right arrow over (ω)} 1 , {right arrow over (ω)} 2 , . . . ]̂∝ K,
[0000] a square matrix whose j th column is k j ∝ {right arrow over (ω)} j . The two key differences in the measurement model presented here are the omission of the (K+σ ε 2 I) −1 term and exclusion of z i WiFi from {right arrow over (z)} WiFi in the weighted average, i.e. [{right arrow over (β)} i ] i =0.
[0048] Omission of (K+σ ε 2 I) −1
[0049] The (K+σ ε 2 I) −1 term can be thought of as a whitening transform on the weighted observations and their weights. If, for example, ten observations appear at the same location {right arrow over (x)} and the same value z, they would collectively only be given one “vote” in the weighted average, rather than ten. This makes sense when attempting to make statistically consistent function value estimates over large distances. Only at small scales can signal strengths be averaged meaningfully without physical modeling of the surrounding materials. At these scales, giving (nearby) past measurements each an “equal vote” provides a larger sample size with which to predict future measurements, which is the methodology employed within the GraphSLAM formulation. Formally, treating past measurements in this way is equivalent to the approximation of
[0000]
e
-
1
2
τ
2
σ
ɛ
2
[0000] for a Gaussian Process, e.g., the measurement noise dominates innate signal variance. At wireless frequencies this is a reasonable assumption. Error in measured signal strength is tightly coupled to innate signal variance by the dynamics of the environment. Distinguishing measurement noise from signal variance would require extensive prior information of building materials, population distributions, etc.
[0050] Furthermore, the size of K grows quadratically in the size of the dataset (number of measurement locations, N). The need to invert K when computing h and its derivatives makes each iteration an O(N 3 ) operation. This is the main reason that it is difficult to scale Gaussian process techniques to larger datasets and omitting this term in the interpolation allows GraphSLAM to achieve a O(N 2 ) asymptotic runtime and in turn makes the GraphSLAM technique easier to scale to larger datasets.
[0051] It should be noted that both GraphSLAM and Gaussian process latent variable models can improve their runtime complexities by means of sparsification or other approximation methods.
Exclusion of z i WiFi
[0052] The second key difference in interpolation methods is that a model fit according to an embodiment of the present invention always excludes z i WiFi from {right arrow over (z)} WiFi when computing the weighted average for h i WiFi . Here, an attempt is made to determine the model fit, or self-consistency, of observing certain measurements. In both GraphSLAM and Gaussian processes, model fit/measurement likelihood is modeled as Gaussian random variables/vectors and as such are defined by their mean and (co)variance. That is, it is desired to determine the fit of z i WiFi . The fit of z i WiFi will be determined by a certain distribution p. In this setting, it would not make sense to use z i WiFi itself to compute the parameters of p.
[0053] As a consequence of including z i WiFi , its own model fit definition, for any fixed τ, the latent space optimization of GP-LVM can improve model fit by moving all points away from each other. To circumvent this behavior, GP-LVM methods almost always require explicit signal strength→location back constraints or carefully selected priors. The GraphSLAM approach according to an embodiment of the invention, on the other hand, will require no hard constraints. Excluding z i WiFi causes measurements to be attracted to similar neighboring measurements. This makes GraphSLAM as an embodiment of the present invention suitable to a wider range of real-world environments, including those where wireless signatures are not rich enough to guarantee uniqueness but still provide enough information to augment an existing SLAM implementation.
[0054] V. Non-Linear Least Squares
[0055] One of the primary appeals of GraphSLAM methods in general is that minimizing the negative log posterior reduces to standard non-linear least squares, giving GraphSLAM access to a vast set of widely used and well-studied techniques for its optimization.
[0056] Here, h pedometry , h gyro , h WiFi , together with Var(ε pedometry ), Var(ε gyro ), Var(ε WiFi ) are needed to formulate the least squares problem:
[0000]
-
log
∏
i
P
Z
i
(
z
i
|
X
)
=
1
2
∑
i
[
z
i
-
h
i
(
X
)
]
T
[
Var
(
ɛ
i
)
]
-
1
[
z
i
-
h
i
(
X
)
]
[0000] Depending on the application, environment, or domain, a uniform prior and maximize the likelihood can be assumed, or any number of Gaussian priors can be added (e.g., inertial priors or smoothness constraints). For the experiments discussed below, uniform priors have been assumed and the data likelihood has been maximized directly.
Solvers
[0057] In general, non-linear least squares is a well-studied problem in numerical optimization communities and any number of solvers can be used instead. Methods such as gradient/steepest descent, Levenberg-Marquardt, BFGS and many Conjugate gradient based methods are readily available and can be applied directly.
[0058] Typical solvers depend on local linearization to iterate toward an optimum. Let J hi (X) denote the derivatives of h with respect to each state variable in X (each row of J is a gradient of h). For example, if this Jacobian is known, any initial guess X 0 can be iteratively refined by solving
[0000]
X
new
:=
X
0
+
[
∑
h
i
J
h
i
T
Ω
h
i
J
h
i
]
-
1
[
∑
h
i
J
h
i
T
Ω
h
i
(
z
i
-
h
i
(
X
0
)
)
]
[0000] with J hi evaluated at X 0 on each iteration. This is known as Gauss-Newton iteration.
[0059] Our results in as described below are obtained using standard Gauss-Newton iteration. In our case, z and h are always scalar valued so J h i (X)=∇h i is a row vector and Ω h i =σ h i −2 is a scalar. Each iteration, then, is equivalent to solving the overconstrained matrix system of the form A{right arrow over (Δ)}={right arrow over (t)}x
[0000]
[
-
σ
h
1
-
1
∇
h
1
-
-
σ
h
2
-
1
∇
h
2
-
⋮
-
σ
h
N
-
1
∇
h
N
-
]
Δ
⇀
=
[
σ
h
1
-
1
(
z
1
-
h
1
)
σ
h
2
-
1
(
z
2
-
h
2
)
⋮
σ
h
N
-
1
(
z
N
-
h
N
)
]
and
updating
X
new
:=
X
0
+
Δ
⇀
State Space
[0060] The convergence characteristics of GraphSLAM, as an embodiment of the present invention, depend on the linearizability of h. In an embodiment, some effort is made to transform the state space to improve linearization. In certain settings, reformulation of a GraphSLAM state space has lead to dramatically improved performance and result quality. So far, all three of the state-to-measurement mappings h pedometry , h gyro and h WiFi are non-linear functions if the world state is represented as X={{right arrow over (x)} t 1 , {right arrow over (x)} t 2 , . . . }, describing robot location at each point in time.
[0061] Due to the exponential terms created by the interpolation weight kernel, h WiFi will be non-linear regardless of the state space parametrization. The state space is solved in terms of the headings {φ 1 , φ 2 , . . . , φ N−1 } and distances {d 1 , d 2 , . . . , d N−1 } between each WiFi scan, e.g.,
[0000]
x
→
=
[
Σ
‵
d
cos
(
φ
)
Σ
d
sin
(
φ
)
]
.
Then
,
h
pedometry
(
X
)
=
d
i
h
gyro
(
X
)
=
φ
i
+
1
-
φ
i
[0000] which linearize with infinite radius of convergence. This allows for eliminating linearization error in all but one of the sensors.
[0062] To compute derivatives ∇ {{right arrow over (d)}, {right arrow over (φ)}} h WiFi (X):
[0000]
∇
{
d
→
,
φ
→
}
h
WiFi
(
X
)
=
[
∇
{
x
→
}
h
WiFi
(
X
)
]
J
{
x
→
}
(
{
d
→
,
φ
→
}
)
∇
{
x
→
}
h
WiFi
(
X
)
=
∑
j
[
β
→
i
]
j
(
z
j
-
h
i
)
-
1
2
τ
2
(
∇
{
x
→
}
x
→
j
-
x
→
2
)
[0000] The gradient of h WiFi (X) under this ‘heading and distance’ parametrization is fast to compute in practice. This is because the columns of J {T} ({{right arrow over (d)}, {right arrow over (φ)}}) are always constant valued with leading zeros, and elements of ∇ {{right arrow over (x)}} ∥{right arrow over (x)} j −{right arrow over (x)} i ∥ 2 are all zero except for those corresponding to the
[0000]
∂
∂
x
→
i
or
∂
∂
x
→
j
[0000] elements.
Experimental Results
Data
[0063] To evaluate the embodiments of the present invention, a trace was used of 536 WiFi scans captured over 17 minutes across a 60 m×10 m area of one floor of a university building. The trajectory covers about 1.2 km of travel distance. This dataset contains corresponding pedometry data, readings from a MEMS gyroscope, and an accompanying LIDAR-derived ground truth. The ground truth has been derived by processing the LIDAR, pedometry, and gyroscope measurements through off-the-shelf LIDAR SLAM.
[0064] Maximizing the likelihood of the dataset over parameter τ yields an optimal value of 2.2 m (e.g., the average distance to a wall in all directions is roughly 4.4 m for 95% of measurement locations), but in our experiments, any values from τ≈1.5 m through τ≈3.5 m all produce good results.
Results
[0065] The ground truth is accurate to about 10 cm. The ground truth and LIDAR are used only to evaluate the results. GraphSLAM requires no labeled data.
[0066] The state space parametrization discussed herein is used. FIG. 3A-C are qualitative visualizations of the performance of the GraphSLAM method according to an embodiment of the present invention. More particularly, shown in FIGS. 3A and 3B are graphs 300 and 302 that compare GraphSLAM initialization ( FIG. 3A ) and the resulting optimized GraphSLAM posterior ( FIG. 3B ). For reference, shown in FIG. 3C is graph 304 that is the unaligned ground truth trajectory.
[0067] By nature of the sensors, GraphSLAM output is displayed in units of steps; ground truth is plotted in meters. Notice that the results show straight halls, despite the GraphSLAM method containing absolutely no explicit shape prior. This adds further confidence to the notion that signal-strength SLAM can be achieved in a completely unsupervised manner, without relying on trajectory priors.
[0068] The sensor used in our experiment measures pedometry in units of steps. The ground truth is collected using a laser-based technique that produces coordinates measured in meters. The location of the nodes in GraphSLAM are in a different reference frame than those in the ground-truth trajectory. To report error in standard units, localization accuracy is computed with a subjective-objective technique: A characterization is made of “how accurately a person detects returning to a previously visited location.” For each time t i during the trajectory, an inferred ‘subjective’ location {tilde over ({right arrow over (x)} t i from GraphSLAM and a true ‘objective’ location {right arrow over (x)}* t i are used for the same timestamp in the ground truth. For every objective location {right arrow over (x)}* t i its ‘objective neighbors’ are denoted to be those points within r meters of {right arrow over (x)}* t i for each objective neighbor of {right arrow over (x)}* t i , the ‘subjective location {tilde over ({right arrow over (x)} t i has a corresponding ‘subjective neighbor’ {tilde over ({right arrow over (x)} t i . The GraphSLAM output is scaled so that the total distance traveled, and define localization error to be the mean of the distance ∥{tilde over ({right arrow over (x)} t i −{tilde over ({right arrow over (x)} t i ∥ 2 across all pairs (t i , t* i ). τ has been chosen to be the mean distance traveled between consecutive WiFi scans.
[0069] With this metric, in an embodiment of the present invention, a mean localization error of 2.23 meters is achieved. The standard deviation of this value is 1.25 m. For comparison, using the same metric, the mean localization error from only pedometry and gyroscope without WiFi is 7.10 m.
[0070] To demonstrate the robustness of an algorithm according to an embodiment of the present invention with respect to parameter selection, FIGS. 4A and 4 B are graphs that shown the mean and standard deviation of the localization error according to an embodiment of the present invention. More particularly, shown in FIG. 4A is graph 400 that is shown over a range of values for the Var(ε WiFi ) parameter. Shown in FIG. 4B is shown over a range of values for the τ parameter. In graphs 400 and 402 , the upper line is +1 standard deviation above the mean, and the lower line is −1 standard deviation below the mean.
[0071] The parameter Var(ε WiFi ), which is related to the measurement noise variance associated with the WiFi sensor, can take any value from roughly 50 through 500 dB. Considering that the WiFi measurements themselves only range from about 0 to −90 dB, this implies that this embodiment is very robust against poor Var(ε WiFi ), selection. The parameter τ, which is related to the expected distance to the nearest wall, needs only be accurate to within roughly 3 meters. This also provides confidence that a slight errors in τ will not cause a catastrophic increase in error.
[0072] These experiments may represent a lower bound on result quality for this algorithm according to an embodiment of the present invention. As a non-linear least squares problem, in general, benefit is expected from more robust solvers, e.g., Levenberg-Marquardt, simulated annealing, etc. Given that the GraphSLAM framework has been well-studied in the SLAM community, any number of solvers are likely to improve performance or result quality further.
[0073] As described above, a signal strength SLAM has been formulated into an instance of GraphSLAM as an embodiment of the present invention. In doing so, scalability has been improved, runtime complexity has been reduced, limitations on WiFi density/richness has been relaxed, and shape priors have been removed. Experimental results on real-world data demonstrate the effectiveness of using GraphSLAM approach to solve this problem. The teaching presented here can be implemented in 3D variants of the WiFi SLAM problem, multi-agent extensions, time-of-arrival/round-trip-time sensor models, improved initialization techniques as well as more specialized solvers as would be obvious to one of ordinary skill in the art upon reading and understanding the present disclosure.
[0074] It should be appreciated by those skilled in the art that the specific embodiments disclosed above may be readily utilized as a basis for modifying or designing other image processing algorithms or systems. It should also be appreciated by those skilled in the art that such modifications do not depart from the scope of the invention as set forth in the appended claims. | In an embodiment of the present invention, a GraphSLAM-like algorithm for signal strength SLAM is presented. This algorithm as an embodiment of the present invention shares many of the benefits of Gaussian processes yet is viable for a broader range of environments since it makes no signature uniqueness assumptions. It is also more tractable to larger map sizes, requiring O(N 2 ) operations per iteration. In the present disclosure, an algorithm according to an embodiment of the present invention is compared to a laser-SLAM ground truth, showing that it produces excellent results in practice. | 7 |
This is a division of copending application Ser. No. 07/952,992 filed on Sep. 29, 1992, now U.S. Pat. No. 5,271,924.
FIELD OF THE INVENTION
The present invention relates to an imaging agent for diagnosis, in particular, to an imaging agent for diagnosis containing a polynuclear type metal complex compound.
BACKGROUND OF THE INVENTION
(Diethylenetriaminepentaacetic acid)gadolinate (hereinafter abbreviated as to "DTPA-Gd") is the only one practical pharmaceutical which is presently known as a nuclear magnetic resonance imaging (hereinafter sometimes abbreviated as MRI) agent for diagnosis [JP-A 58-29718] and it is considered that the use thereof as an imaging agent for diagnosis in the brain or spinal regions has been almost established. Since, however, DTPA-Gd is complexed, the relaxivity showing the image display index is lower (about 1/2) than that of Gd itself. Therefore, it is necessary to compensate this lowered relaxivity by increasing the dose. In addition, DTPA-Gd is rapidly excreted into the urine after administration [Hiroki Yoshikawa et al., Gazoshindan, 6, pages 959-969 (1986)], and this is very disadvantageous for imaging of several parts of the body by reflecting them in blood stream (blood vessel distribution, blood stream distribution, distribution volume, permeation and the like in a lesion) with a single injection of the pharmaceutical. Further, such rapid excertion also makes distribution properties of DTPA-Gd disadvantageous.
For solving the above-described problems (improvement in the relaxivity), some attempts at polynuclearization by repetition of mononuclear complex are described in JP-A 63-41468, JP-A 2-196776 and the like. Since, however, the poly-nuclearization is limited at best to di-nuclearization or tri-nuclearization, remarkable improvement in relaxivity can not be recognized.
Thereafter, the use of a polynuclear type metal complex compound obtained by introducing a plurality of metal complexes into a carrier polymer material as an imaging agent for diagnosis used as has been investigated. As a result, a MRI agent for diagnosis the carrier of which is human serum albumin (abbreviated as "HSA") [Ogan, M. D., et al., Invest. Radiol., 22, pages 665-671 (1987)], dextran [Brash, R. C., et al., Radiology, 175, pages 483-488 (1990)], starch [JP-A 61-501571], polylysine [JP-A 64-54028] or the like has been proposed and succeeded in improvement of relaxivity. These polymer polynuclear type metal complex compounds are localized in blood vessel for a constant period of time from immediately after administration and have the common distribution properties as retention in blood vessel for a relatively long period of time, which also improves the rapid excretion and penetration properties of DTPA-Gd.
However, the polymer carriers which can be a backbone for these polynuclear type metal complexes, regardless of a natural or synthetic material, is a heterogeneous compound the molecular weight of which has no mono-dispersion and is dealt with as an average value having a certain distribution width. Therefor, there is a problem that pharmaceutical uniformization can not be attained. For this reason, it is very difficult to control the number of metal ion to be introduced at constant and, therefore, heterogeneity arises inevitably in the objective physicochemical properties. Further, since all of the above-described polymers have the molecular weight more than tens of thousands, they have an unnecessarily long retention time in blood such as from ten and a few hours to a few days and have problems on biological acceptability as retention in the body, antigenicity and the like.
OBJECTS OF THE INVENTION
The main object of the present invention is to provide an imaging agent for diagnosis comprising a polynuclear type metal complex compound which can solve the above-described problems in the known imaging agents for diagnosis containing a polymer polynuclear type metal complex compound. Namely, the main object of the present invention is to provide an image agent for diagnosis having a plurality of metal ions which are stably introduced in the desired number, good homogeneity, good solubility, physiologically acceptability and suitable retention time in blood for image diagnosis.
This object as well as other objects and advantages of the present invention will become apparent to those skilled in the art from the following description with reference to the accompanying drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a MRI showing a transverse view of the chest region including the heart of a rat sacrificed at 1 hour after administration of a (galactosamino-pentamer)-[1-(p-isothiocyanatebenzyl)-diethylenetriaminepentaacetic acid]gadolinate (abbreviated as "GPEN-DTES-Gd") solution.
FIG. 2 is a MRI showing a transverse view of the chest region including the heart of a rat sacrificed at 1 hour after administration of DTPA-Gd (MAGNEVIST®).
SUMMARY OF THE INVENTION
In order to accomplish the above-described objects, the present inventors studied extensively. As a result, it has been found that a polynuclear type metal complex compound having as a backbone a chitosan-oligosaccnaride or qaiactosamino-oligosaccharide and has a clinically effective retention in blood.
For example, the present inventors have investigated in vitro or in vivo relaxivity and contrast effect of a polynuclear type metal complex compound GPEN-DTES-Gd, wherein 1-(p-isothiocyanatebenzyl)-DTPA (abbreviated as to "DTES") [Martin, W. B., et al., Inorg. Chem., 25, pages 2772-2781 (1986)] is chemically bonded as a bifunctional ligand to galactosamino-pentamer (abbreviated as "GPEN") and Gd is coordinated therewith as a metal ion. As a result, it has been confirmed that T 1 relaxivity in water (magnetic field intensity: 6.35T, 25° C.) is remarkably increased to 7.6 (mM·S) -1 , being about two times that of DTPA-Gd. Further, it has been confirmed that the contrast effects (magnetic field intensity: 1.5T, T 1 weighted imaging by spin echo method) in the heart of a rat at 1 hour after administration is enhanced by about 1.8 times that of DTPA-Gd imaged under the same conditions. Furthermore, GPEN-DTES-In-111 labeled with a radioactive metal ion, In-111, has half-life period in blood of about 55 minutes in the distribution test in rats. This half-life period in blood is sufficiently longer than that of DTPA-In-111, and shows good retention in blood.
The present invention has been completed based on these findings and provides an imaging agent for diagnosis comprising a compound composed of a polynuclear type compound of the formula I or II: ##STR2## wherein each X is a hydrogen atom or a bifunctional ligand, at least one of them are a bifunctional ligand and each of m and n is an integer of 1 to 6, and at least one metal ion being coordinated with at least of one bifunctional ligand moiety, said metal ion being selected from the group consisting of metal ions having the atomic number of 21-29, 31, 32, 37-39, 42-44, 49 and 56-83.
DETAILED DESCRIPTION OF THE INVENTION
The term "polynuclear type" as used herein means a structure wherein a plurality of metal ions are introduced therein via a complexing agent per unit molecule.
The compound used as a backbone for polynuclearization in the present invention is an amino oligosaccharide, more particularly, a chitosanoligosaccharide or galactosamino-oligosaccharide. In particular, an oligomer having the repetition number of component monosaccharide of 3 to 6 (m or n is 1 to 4 in the formula I or II) is advantageously used. The chitosan-oligosaccharide is an oligosaccharide wherein D-glucosamine monomers are bonded through β-1,4 bond. The chitosanoligosaccharide to be used can be obtained, for example, by hydrochloric acid-hydrolyzing or enzymatically degrading chitosan prepared from natural crab shell. On the other hand, the galactosamino-oligosaccharide has a structure wherein D-galactosamine monomers are polymerized through α-1,4 bond. The galactosamino-oligosaccharide to be used can be obtained, for example, by hydrolyzing natural polygalactosamine produced by imperfect fungi, Paecilomyces with an acid or enzyme. Since both chitosan and galactosamino-oligosaccharide are a reactive molecule having a high reactive amino group at 2-position in the component monosaccharide, the complicated derivation is not required for bonding with a ligand. As a result, a reaction with a bifunctional ligand can be completed in a single step.
Respective oligosaccharides are fractionated in high purity by chromatography according to the degree of polymerization and these oligosaccharides having uniform molecular weight are commercially available. Therefore, the number of bifunctional ligands and metal ions to be introduced can be precisely controlled and it is possible to prepare a pharmaceutically homogenous polynuclear type metal complex compound. In addition, both of them have high compatibility with the living body and physiological acceptability.
As the bifunctional ligand, there can be used linear or cyclic polyaminopolycarboxylic acids having a cross-linking chain moiety which can bond to the amino group at 2-position of the amino oligosaccharide as a backbone. The preferred bifunctional ligand is a ligand having as a coordinating partial structure the skeleton of DTPA or derivative thereof, or the skeleton of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid (abbreviated as "DOTA") or a derivative thereof. As the reactive group in the cross-linking chain part of bifunctional ligand which can bond to the amino group at 2-positional, i.e., the reactive functional group, active halogen, alkoxyester, succinimidiester, isothiocyanate, acid anhydride and the like are preferred. More particularly, there are 1-(p-isothiocyanatebenzyl)-DTPA [Martin, W. B., et al., Inorg. Chem., 25, pages 2772-2781 (1986), DTPA anhydride, 2-(p-isothiocyanatebenzyl)-1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid [U.S. Pat. No. 4,678,667] and the like.
The bond between the amino-oligosaccharide and the bifunctional ligand can be formed according to a per se known method. For example, a reaction of the bifunctional ligand having as the cross-linking chain terminal an acid anhydride [Hnatowich, D. J., et al., Int. J. Appl. Rad. Isot., 33, pages 327-332 (1982)], isothiocyanate [Esteban, J. M., et al., J. Nucl. Med., 28, pages 861-870 (1987)], alkoxyester [Washburn, L. C., et al., Nucl. Med. Biol., 18, pages 313-321 (1991)] or active halogen [Fourie, P. J., et al., Eur. J. Nucl. Med., 4, pages 445-448 (1979)] with the amino-oligosaccharide can be carried out according to the description in the above cited known publications.
In the present invention, the metal ion is selected from the group consisting of metal ions having the atomic number of 21-29, 31, 32, 37-39, 42-44, 49 and 56-83 depending upon a particular use of image diagnosis. When the polynuclear type metal complex of the present invention is used for MRI diagnosis, the metal ion must be paramagnetic and is selected from the ions of the atomic number of 26 and lanthanide having the atomic number of 57-70. The metal ion is preferably an ion of Gd, Dy, Tb, Ho, Er or Fe. When used for X-ray diagnosis, the metal ion is selected from the lanthanide element ions having the atomic number of 57-70 and the ions of the element having the atomic number of 56, 76, 82 and 83. The metal ion preferably an ion of Bi, Pb or Os. For radiation diagnosis, the metal ion must be radioactive and is suitably the radioactive metal ion such as Co, Cu, Ga,. Ge, Sr, Y, Tc, In, Sm, Gd, Yb, Re or Ir. As the metal ion, there can be used a metal itself or inorganic compound thereof (for example, chloride, oxide). Complexation can be carried out by a conventional method.
In the polynuclear type metal complex compound thus obtained, at least one, preferably, two or more bifunctional ligands are chemically bonded to chitosan-oligosaccharide or galactosamino-oligosaccharide and the metal ions are bonded to this coordinating moiety through a complexing bond.
The polynuclear type metal complex compound can be formulated into an imaging agent for diagnosis in any suitable dosage form by mixing with any suitable pharmaceutically acceptable additive according to a conventional method and, preferably, formulated into an imaging agent for diagnosis in a solution form by dissolving it in a physiologically acceptable aqueous solvent.
When the polynuclear type metal complex compound of the present invention is used for imaging agent for diagnosis, the dose to be used is selected depending upon a particular use of image diagnosis. For example, for MRI diagnosis, the dose is generally 0.0001 to 10 mmol/kg, preferably, 0,005 to 0.5 mmol/kg in terms of the metal ion. For X-ray diagnosis, the dose is 0.01 to 20 mmol/kg, preferably, 0.1 to 10 mmol/kg in terms of the metal ion. Further, for radiation diagnosis, the dose is 370-18500 MBq in terms of radioactivity. Usually, the imaging agent is administered intravenously and, in some cases, can be administered orally or intra-arterially.
The retention in blood of the polynuclear type metal complex compound of the present invention is in a clinically effective range (half-life period in blood of 0.5 to 5 hours). Thus, it is possible to suitably combine the imaging agent with a particular MRI apparatus having a different magnetic field intensity by appropriately selecting the polymerization degree of the amino oligosaccharide. For example, in the case of low magnetic field intensity MRI apparatus, the use of the imaging agent for diagnosis having a relatively long retention time in blood is preferred in order to improve the collection efficacy of proton relaxation effect by the imaging agent. In addition, the polynuclear type metal complex compound of the present invention has the advantage of having the higher contrast efficacy per unit dose. For example, when Gd is contained as the metal ion, the shortening effect of the relaxation time per molecule is superior to that of DTPA-Gd, the polynuclear type metal complex compound can be used advantageously as a MRI diagnostic agent. This improves the detection efficacy in an another sense in the diagnosis by low magnetic field MRI apparatus having a low collection efficacy of proton relaxation effect, resulting in the shortening of the imaging time. Further, when the same contrast effect as that of DTPA-Gd in an apparatus having the same magnetic field intensity is required, the polynuclear type metal complex compound of the present invention can be administered in a smaller dose than DTPA-Gd and, therefore, becomes more advantageous in view of safety. To the contrary, at the same dose, the polynuclear metal complex compound of the present invention provides more informations about the living body than DTPA-Gd, resulting in the improvement in the clinical usefulness. Therefore, the present invention can provide the imaging agent having suitable retention in blood, matching with the magnetic field intensity of a MRI apparatus and imaging conditions, as well as effective contrast effect.
Further, since the polynuclear type metal complex compound of the present invention shows the suitable retention in blood, the evaluation of the blood vessel distribution image (vascularity) becomes possible. Therefore, the imaging agent for diagnosis of the present invention can image the blood vessel without pulse sequence which is particularly necessary for recently remarkably advanced MR angiography, and the agent is also useful as a diagnostic imaging agent for intravenous injection.
Since the polynuclear type metal complex compound of the present invention has good solubility in water, the compound itself can be prepared as a solution containing the compound in a high concentration. Accordingly, a solubilizer is not necessarily required upon preparation of the solution. In addition, the metal complex compound of the present invention is a polynuclear compound and, therefore, can decrease the total molality in the preparation of a solution in comparison with the mononuclear compound, which results in the decrease in osmotic pressure. These alleviate the load to volume of the circulatory system or body fluid equilibrium upon administration in the living body, which resulting in advantage in the safety.
As described herein above, the imaging agent of the present invention comprises the polynuclear type metal complex wherein a plurarity of metal ions are chemically bonded thereto via a plurality of the bifunctional ligands which are chemically bonded to the chitosan-oligosaccharide or galactosamino-oligosaccharide. By using this novel and special polynuclear type metal complex compound, image diagnosis such as MRI diagnosis, X-ray diagnosis, radiation diagnosis and the like can be efficiently carried out.
The following Examples and Tests further illustrate the present invention in detail but are not to be construed to limit the scope thereof.
The abbreviations used in Examples and Tests mean as follows:
GPEN: galactosamino-pentamer
CHEX: chitosan-hexamer
GTRI: galactosamino-trimer
CPEN: chitosan-pentamer
DTPA: diethylenetriaminepentaacetic acid
DTES: 1-(p-isothiocyanatebenzyl)-diethylenetriaminepentaacetic acid
DOTA: 1,4,7,10-tetraazacyclododecane-l,4,7,10-tetraacetic acid
ICB-DOTA: 2-(p-isothiocyanatebenzyl)-l,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid.
EXAMPLE 1
Synthesis of GPEN-DTES
GPEN (0.39 g; 0.43 mmol) was dissolved in 0.1M phosphate buffer (pH 7.0) (2 ml) and DTES (0.70 g; 1.3 mmol) was added thereto. 10N Aqueous solution of sodium hydroxide was added thereto to adjust pH to about 12, and the mixture was reacted at room temperature for 24 hours with stirring. To the reaction mixture was added 7N hydrochloric acid to neutralize to obtain crude GPEN-DTES.
A portion of the reaction mixture (50 μl) was taken out and 0.1M citrate buffer (pH 5.9) (100 μl) and a solution (50 μl) of indium chloride (In-111) were admixed with the reaction mixture. The ratio of GPEN-DTES-In-111 and DTES-In-111 was determined by thin layer chromatography and it was confirmed that 1.4 molecules of DTES were bonded per GPEN molecule.
The above reaction mixture was concentrated and purified by preparative thin layer chromatography (silica gel) to obtain GPEN-DTES (0.24 g).
Proton-nuclear magnetic resonance (NMR) spectrum (solvent/D 2 O, 270MHz): 2.10-3.37 ppm (10H, m, CH 2 ), 3.49-4.55 ppm, 4.88-5.59 ppm (m, CH, CH 2 and NH), 4.22 ppm(1H, bs, N-CH), 7.07-7.40 ppm (4H, m, benzene ring)
Infrared absorption (IR) spectrum (KBr tablet): 810 cm -1 (CH of benzene ring), 1100 cm -1 (OH), 1400cm -1 (CH 2 ), 1590 cm -1 (COOH)
EXAMPLE 2
Synthesis of GTRI-DTES
GTRI (6.4 mg; 0.01 mmol) was dissolved in 0.1M phosphate buffer (pH 7.0) (1 ml) and DTES (17.4 mg; 0.03 mmol) was added thereto. 10 N Aqueous solution of sodium hydroxide was added thereto to adjust pH to about 12, and the mixture was reacted at room temperature for 24 hours with stirring. To this reaction mixture was added 7N hydrochloric acid to neutralize to obtain crude GTRI-DTES.
A portion of the reaction mixture (50 μl) was taken out and 0.1M citrate buffer (pH 5.9) (100 μl) and a solution (50 μl) of indium chloride (In-111) were admixed with the reaction mixture. The ratio of GTRI-DTES-In-111 and DTES-In-111 was determined by thin layer chromatography and it was confirmed that 3 molecules of DTES were bonded per GTRI molecule.
The above reaction mixture was concentrated and purified by preparative thin layer chromatography (silica gel) to obtain GTRI-DTES (11.0 mg).
Proton-NMR spectrum (solvent/D 2 O, 270 MHz): 2.20-3.58 ppm (10H, m, CH 2 ), 3.58-4.63 ppm, 4.95-5.65 ppm (m, CH, CH 2 and NH), 4.30 ppm (1H, bs, N-CH), 7.15-7.45 ppm (4H, m, benzene ring)
IR spectrum (KBr tablet): 810 cm -1 (CH of benzene ring), 1070 cm -1 (OH), 1400 cm -1 (CH 2 ), 1625 cm -1 (COOH)
EXAMPLE 3
Synthesis of CPEN-DTPA
CPEN (0.08 g; 0.08 mmol) was dissolved in water (2 ml) and 4N aqueous solution (1.2 ml) of sodium hydroxide was added thereto. DTPA anhydride (0.57 g; 1.59 mmol) was added thereto immediately, and the mixture was reacted at room temperature for 3 hours with stirring to obtain crude CPEN-DTPA.
A portion of the reaction mixture (0.2 ml) was taken out and 0.1M citrate buffer (pH 5.9) (0.2 ml) and a solution (0.025 ml) of indium chloride (In-111) were admixed with the reaction mixture. The ratio of CPEN-DTPA-In-111 and DTPA-In-111 was determined by thin layer chromatography and it was confirmed that 4.5 molecules of DTPA were bonded per CPEN molecule.
The above reaction mixture was concentrated and purified by preparative thin layer chromatography (silica gel) to obtain CPEN-DTPA (0.08 g).
Proton-NMR spectrum (solvent/D 2 O, 270 MHz): 2.0 ppm (H, s, CH 2 ), 3.1-3.3 ppm (m, CH 2 ), 3.4-3.6 ppm (m, CH 2 ), 3.8 ppm(4H, s, CH 2 )
IR spectrum (KBr tablet): 1090 cm -1 (OH), 1400 cm -1 (CH 2 ), 1600 cm -1 (COOH)
EXAMPLE 4
Synthesis of CPEN-(ICB-DOTA)
CPEN and ICB-DOTA are dissolved in 0.1M phosphate buffer (pH 7.0), and the solution is reacted at room temperature while maintaining pH at 12 to obtain CPEN-(ICB-DOTA).
EXAMPLE 5
Preparation of GPEN-DTES-Gd solution
GPEN-DTES (0.30 g; 0.18 mmol) was dissolved in distilled water (2 ml). Gadolinium chloride hexahydride (0.06 g; 0.17 mmol) was added thereto and the mixture was reacted at room temperature with stirring to obtain GPEN-DTES-Gd. The absence of free Gd was confirmed by a color developing reaction using Xylenol Orange as a pigment indicator.
Gd concentration (ICP emission analysis): 75.1 mM
EXAMPLE 6
Synthesis of Gd complex
Gd complex of the relevant compound is obtained by the same manner as that described in Example 5 except that GPEN-DTES is substituted by GTRI-DTES, CPEN-DTPA and CPEN-(ICB-DOTA).
EXAMPLE 7
Preparation of GPEN-DTES-In-111 solution
GPEN-DTES (10 mg) was dissolved in distilled water (0.5 ml) and 0.1M citrate buffer (pH 5.9) (1 ml) was added thereto. A solution (0.5 ml; 148 MBeq) of indium chloride (In-111) was admixed to obtain GPEN-DTES-In-111. Its radiochemical purity was 100%.
EXAMPLE 8
Synthesis of CHEX-DTPA-Bi
CHEX-DTPA (0.45 g; 0.13 mmol) synthetized according to the same manner as that described in Example 3 was dissolved in distilled water (30 ml). Bismuth chloride (0.28 g; 0.88 mmol) was added thereto, pH was adjusted to about neutral by addition of 4N aqueous solution of sodium hydroxide. The mixture was reacted at 60° C. for 18 hours with stirring. The insoluble materials were filtered off and the filtrate was purified through a desalting apparatus (manufactured by Asahikasei K. K., Japan). The purified solution was concentrated and dried to obtain CHEX-DTPA-Bi (0.54 g). The absence of free Bi was confirmed by a color developing reaction using Xylenol Orange as a pigment indicator.
IR spectrum (KBr tablet): 1070 cm -1 (OH), 1393 cm -1 (CH 2 ), 1458 cm -1 (CONH), 1582 cm -1 (COO - )
Quantitative analysis of Bi (ICP emission analysis): 0.11 g
Test 1
Relaxivity of GPEN-DTES-Gd and GTRI-DTES-Gd (in vitro test)
An appropriate amount of GPEN-DTES-Gd and GTRI-DTES-Gd were dissolved in distilled water. The relation to water proton exposed to these compounds was determined as a proton relaxation time (T 1 and T 2 , msec) at room temperature (24° to 26° C.) using NMR (6.35T, manufactured by Nihondenshi K. K., Japan). Respective relaxation times are shown in Tables 1 and 2.
TABLE 1______________________________________Relaxation time of GPEN-DTES-GdConcentration (mM) T.sub.1 (msec) T.sub.2 (msec)______________________________________2.3 55 260 3275 2208______________________________________
TABLE 2______________________________________Relaxation time of GTRI-DTES-GdConcentration (mM) T.sub.1 (msec) T.sub.2 (msec)______________________________________2.9 46 260 3275 2208______________________________________
GPEN-DTES-Gd (2.3 mM) shortened remarkably the T 1 value of water about 60 times and the T 2 value of water 85 times. And GTRI-DTES-Gd (2.9 mM) shortened remarkably the T 1 value of water about 70 times and the T 2 value about 85 times. The relaxivity on T 1 and T 2 [each R 1 and R 2 , (mM·S) -1 ] were calculated based on the values in Tables 1 and 2. The results are shown in Table 3.
TABLE 3______________________________________Relaxivity of GPEN-DTES-Gd and GTRI-DTES-GdCompound R.sub.1 (mM · S).sup.-1 R.sub.2 (mM · S).sup.-1______________________________________GPEN-DTES-Gd 7.6 16.2GTRI-DTES-Gd 7.4 13.1DTPA-Gd 3.9 4.8______________________________________
GPEN-DTES-Gd and GTRI-DTES-Gd have good in vitro relaxation effect and the effect is predominantly higher than that of DTPA-Gd (also shown in Table 3) which is mononuclear complex, determine according to the same manner. The results clearly show the effectiveness of GPEN-DTES-Gd and GTRI-DTES-Gd.
Test 2
Relaxation time of GPEN-DTES-Gd in blood in mouse after intravenous administration (ex vivo test)
GPEN-DTES-Gd (Gd concentration: 75 mM) (0.025 mmol/kg in terms of Gd) was administered to a thiopental anesthetized ICR female mouse (body weight: 44 g) through the tail vein. At 15 minutes after administration, the blood was taken from the aorta descendence, and the relaxation time (T 1 , msec) of the blood at room temperature (24° to 26° C.) was determined with a 6.35T NMR apparatus (manufactured by Nihondenshi K. K., Japan).
As a control, blood was taken from the aorta descendence of a thiopental anesthetized ICR female mouse (body weight: 55 g) and, according to the same manner, the relaxation time was determined. The results are Table 4.
TABLE 4______________________________________Relaxation time of GPEN-DTES-Gd in bloodAdministered compound T.sub.1 in blood (msec)______________________________________GPEN-DTES-Gd 769control 1769______________________________________
T 1 relaxation time of GPEN-DTES-Gd in blood is about 2.3 times effect compared with that of the control mouse and it has been found that the relaxation time of the blood is effectively shortened.
Test 3
Contrast enhancement of the heart in rat at 1 hour after intravenously administration of GPEN-DTES-Gd (in vivo test)
A solution of GPEN-DTES-Gd (Gd concentration: 75.1 mM) (0.094 mmol/kg in terms of Gd) was administered to a thiopental anesthetized Sprague-Dawley female rat (214 g, 9-weeks old) through a cannula fixed to femoral vein. At 1 hour after administration, the animal was sacrificed by administration of pentobarbital solution (1 ml) through the above cannula, fixed at prone position in the magnetic field of a MRI spectrometer. MRI measurement (transverse sectional view) of the chest region including the heart was carried out.
As a control, DTPA-Gd (MAGNEVIST®) was administered to a Sprague-Dawley female rat (body weight: 204 g, 9-weeks old) through a cannula fixed at femoral vein (0.1 mmol/kg) and the measurement (transverse sectional view) of the chest region including the heart was carried out as described above.
The apparatus was SIGMA (manufactured by GE, U.S.A.) with magnetic field intensity of 1.5T and, as an imaging coil, a 26 cm φ bird-cage type head QD coil was used. Imaging was carried out according to spin echo method of T 1 weighted (TR/TE, 600/30 msec) under the condition of 10 mm in slice thickness, a resolution of 256×128.
The signal intensity from the rat to which GPEN-DTES-Gd was administered was found to be about 1.8 times higher than that of the rat to which MAGNEVIST® was administered when comparing the signal intensity from the same part of the heart, The superiority in retention in blood of GPEN-DTES-Gd over that of DTPA-Gd together with the dose of Gd demonstrated the advantages of the present invention.
Test 4
Radioactivity-distribution in blood and urine after intravenous administration of GPEN-DTES-In-111 (in vivo test)
Sprague-Dawley female rats (three rats/mesurement time) (body weight: 110 to 130 g) were anesthetized with thiopental and GPEN-DTES-In-111 solution prepared in Example was administered through the tail vein (50 μl/rat). The animals were sacrificed by dehematization at 0.25, 0.5, 1, 3, 6 and 24 hours after administration. The blood and bladder were removed and the radioactivity was measured. The radioactivity distribution ratio in blood and urine at each measurement time are shown in Table 5.
TABLE 5______________________________________Radioactivity distribution ratio ofGPEN-DTES-In-111 in blood and urineTime (hr) Blood (%/dose) Urine (%/dose)______________________________________ 0.25 4.63 ± 1.65 51.23 ± 1.400.5 2.63 ± 0.86 66.07 ± 3.451.0 2.72 ± 0.40 77.13 ± 3.363.0 1.92 ± 1.06 81.43 ± 6.236.0 0.67 ± 0.35 87.04 ± 4.6824.0 0.16 ± 0.12 90.12 ± 3.57______________________________________
As seen from the results in Table 5, the half-life period of GPEN-DTES-In-111 in blood was about 55 minutes and was found to be clinically effective retention in blood. Since excretion into the urine was good, there was no problem of residence in the body. | There is disclosed an imaging agent for diagnosis comprising a compound composed of a polynuclear type compound of the formula I or II: ##STR1## wherein each X is a hydrogen atom or a bifunctional ligand, at least one of them are bifunctional ligand and m or n is an integer or 1 to 6, and at least one metal ion being coordinated with at least one bifunctional ligand moiety, said metal ion being selected from the group consisting of metal ions having the atomic number of 21-29, 31, 32, 37-39, 42-44, 49 and 56-83. | 8 |
[0001] This application is a National Phase of PCT International Application No. PCT/EP2012/066672, filed Aug. 28, 2012, which claims priority under 35 U.S.C. §119 from German Patent Application No. 10 2011 081 801.4, filed Aug. 30, 2011 and German Patent Application 10 2012 016 844.6, filed Aug. 27, 2012, the entire disclosures of which are herein expressly incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The invention relates to a radial turbocompressor having at least two compressor stages, wherein a motor drives radial impellers of the compressor stages which are arranged on a shaft, wherein the motor and the compressor stages are arranged in a common housing and a medium enters the housing through an intake opening, and wherein one part of the medium is guided through the motor and another part flows past the motor, both parts are then brought back together, are compressed and exit the housing through a discharge opening.
[0003] Both blowers and compressors can be used for the delivery of gases, the fundamental differences being in their construction and field of application. In contrast to compressors, blowers are set up for high flow rates and produce only a small increase in pressure.
[0004] German patent document no. DE 60016886 T2 describes a blower acting as an air pump and used for inflating air mattresses, bicycle tires or sports balls. The air is delivered by impeller wheels which are arranged in a housing made of hard plastic.
[0005] As their name suggests, compressors are set up for compressing gases. During this process, and under appropriate operating conditions, the gas can also enter a supercritical state. The turbocompressor according to the invention is preferably used for the delivery of carbon dioxide. During the compression step, the carbon dioxide passes from a gaseous state to a supercritical state as the critical temperature is only 31.0° C. and carbon dioxide has a relatively low critical pressure of just 73.8 bar. The carbon dioxide is sometimes already in a supercritical state upon entry to the compressor. In order to encompass both gases and supercritical fluids, reference is made in the context of the invention to a medium which is compressed.
[0006] Compressors can operate either according to the displacement principle or the dynamic principle. In the case of the displacement principle, compression is achieved by enclosing a body of gas and then reducing the space in which the gas is contained. Examples of compressors operating according to the displacement principle are reciprocating-piston compressors and rotary piston compressors.
[0007] By contrast, the present invention relates to compressors operating according to the dynamic principle. In the case of the dynamic principle, the gas is strongly accelerated in an impeller and is compressed by deceleration in a downstream diffuser. Compressors operating according to the dynamic principle are called turbocompressors.
[0008] Turbocompressors fall into one of two main types: axial turbocompressors and radial turbocompressors. In axial turbocompressors, the gas flows through the compressor in a direction parallel to the shaft.
[0009] The present invention relates to radial turbocompressors. The gas flows axially into the impeller of the compressor stage and is then accelerated, by centrifugal force, radially outward in the impeller intermediate space which narrows in the manner of a nozzle. The gas leaves the impeller intermediate spaces with great speed at the impeller circumference and flows into the diffuser. In the case of conventional radial turbocompressors, after the last compressor stage, the gas flows away radially outward through a pressure pipe oriented vertically with respect to the rotor axis.
[0010] The compressor stages are driven by a motor. The electric motor comprises a rotor and a stator. In the case of the present invention, the rotor and the radial impellers are arranged on a common shaft.
[0011] The prior art discloses embodiments in which the compressor stages and the motor are in each case surrounded by an individual housing, wherein the motor shaft leaves the motor housing and enters the compressor stage housing.
[0012] By contrast, in the case of the present invention, the motor and the compressor stages are arranged in a common housing. The gas enters the housing through an intake opening. The uncompressed medium first flows past the motor and is then compressed. After passing through the compressor stages, the medium leaves the housing through a discharge opening.
[0013] In the case of conventional radial turbocompressors, the housing is often split horizontally. During assembly, the shaft together with the impellers is placed in the lower half of the housing. The upper half of the housing contains the intake pipe and the pressure pipe, which are formed perpendicularly outward on the upper half of the housing. The two halves are then brought together. The medium is supplied and removed through the pipes which project vertically outward with respect to the axis of rotation of the shaft.
[0014] Turbocompressors often have to be integrated inside a machine building. This often raises problems in terms of space, owing to the arrangement of many other apparatus and machines. In addition, largely vibration-free operation of the turbocompressor has to be guaranteed in order that neither the machine itself nor adjacent apparatus are damaged. To this end, costly mounting of the rotor by means of axial and radial bearings is necessary. Costly bearing constructions are necessary in order to compensate for the axial force of the impellers.
[0015] Against this technical backdrop, the present turbocompressor is constructed in such a manner that it has a compact and stable construction and compensates for the axial force in a simple and cost-effective manner by virtue of the fact that the discharge opening is arranged centrally in the axial direction with respect to the axis of rotation of the shaft.
[0016] In the final compressor stage, the medium first flows through a radial impeller and is then guided into a diffuser. A return duct feeds the medium to the axial discharge opening.
[0017] In contrast to conventional turbocompressors, the medium leaves the housing not through a pressure pipe arranged radially with respect to the shaft but through a discharge opening arranged axially with respect to the axis of rotation of the shaft. The housing is embodied as a compact pressure vessel whose cylindrical casing does not have any disruptive pressure pipes but instead a discharge opening on the end face of the pressure vessel. The connection flanges employed in the case of the present invention are very stable in comparison to pressure pipes which lead away perpendicularly.
[0018] The axial arrangement of the discharge opening, centrally with respect to the shaft, means that the outlet pressure of the medium in the axial direction acts as a reaction force on the outlet-side end of the shaft. This compensates for the axial force.
[0019] Preferably, the intake opening of the turbocompressor is also arranged centrally in the axial direction with respect to the axis of rotation of the shaft. The housing, embodied as a cylindrical pressure vessel, then has no pipes on the casing surface. Both the supply and removal of the medium occur via the end faces of the cylindrical pressure vessel. The end faces are preferably formed as curved bases on the casing part of the pressure vessel. The circular intake opening is introduced into the center of one base. The circular discharge opening is introduced into the center of the opposite base.
[0020] The described compressor very efficiently compresses the medium which is guided through, although a considerable quantity of heat can nonetheless be released in the motor. It is an object of the invention to simply and cost-effectively remove the waste heat generated.
[0021] The impellers of the turbocompressor are preferably driven by an electric motor having a rotor and a stator. In an embodiment of the compressor according to the invention, the medium is split into two partial flows, wherein a first partial flow of the medium is guided past between the stator of the motor and a static component of the turbocompressor and a second partial flow is fed through the motor, in particular between the rotor and stator of the motor. The static component can be the housing itself or a component connected to the housing. The medium which is guided past takes up heat and thus serves to cool the motor. After passing the motor region, the two partial flows are reunited and enter the first compressor stage, in which the medium is compressed. In one variation, the second partial flow can also be guided through the stator of the motor. Corresponding ducts must be provided to this end.
[0022] In an advantageous configuration of the invention, bearings, in particular radial bearings and axial bearings, are arranged between the motor and the impellers. The arrangement at this location prevents excessive heating of the bearings as the medium is not yet in a compressed state.
[0023] For further cooling of the device, it is proposed that the surface be configured so as to favor a transfer of heat between the individual components of the compressor and the medium. To that end, the surface of the components is to be roughened so as to increase the surface area while at the same time markedly preventing the formation of eddies. If this transfer is carried out at a point at which the medium is not yet compressed, the temperature difference between the medium and the components is very large, thus favoring the process.
[0024] The present invention is very advantageously employed for use in a heat pump in which a heat transfer medium is pumped. The heat produced by the motor is supplied to this heat transfer medium, thus increasing an increase in the overall efficiency of such an installation as practically no electrical power is lost. The waste heat from the motor can be directly recovered upon compression of the heat transfer medium.
[0025] In one advantageous configuration, CO2 is used as heat transfer medium. This gas is chemically harmless and is available at low cost almost everywhere. For use in a heat pump, it can be employed in the critical region, where the physical properties can be used to particularly good effect.
[0026] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of one or more preferred embodiments when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a turbocompressor in accordance with an embodiment of the present invention in axial section,
[0028] FIG. 2 shows the guiding paths of the medium of FIG. 1 in the turbocompressor,
[0029] FIG. 3 is a perspective representation of the compressor stages of FIG. 1 ,
[0030] FIG. 4 shows the FIG. 3 compressor stages in axial section,
[0031] FIG. 5 is a perspective cutaway representation of the housing of the turbocompressor of FIG. 1 ,
[0032] FIG. 6 a is a perspective view of a radial impeller in accordance with an embodiment of the present invention, and
[0033] FIG. 6 b is a perspective view of the FIG. 6A radial impeller, represented without a cover disk.
DETAILED DESCRIPTION
[0034] FIG. 1 shows an axial section through an oil-free turbocompressor which, in the exemplary embodiment, is designed for the delivery of carbon dioxide. The guiding paths of the carbon dioxide are represented in FIG. 2 . In the following, both figures are referred to in parallel, where the components are detailed in FIG. 1 and FIG. 2 shows the guiding paths.
[0035] The carbon dioxide enters the housing 2 of the turbocompressor through the intake opening 1 . In the exemplary embodiment, the carbon dioxide has at the intake opening 1 a pressure of 38 bar and a temperature of 8° C. The carbon dioxide flow splits into two partial flows 3 , 4 .
[0036] The as-yet uncompressed carbon dioxide flows past the motor 5 of the turbocompressor. The motor 5 is embodied as an electric motor. It is a two-pole permanent magnet machine rotating, at the reference point, at 141,000 rpm. The motor 5 is arranged on the low-pressure side of the compressor. It comprises a rotor 6 and a stator 7 . The active part of the rotor 6 consists of a cylindrical, diametrically magnetized solid magnet. The magnet is encased on account of its mechanical properties.
[0037] The stator 7 is made up of individual metal plates. The grooves are insulated from copper windings by an insulating foil. The motor 5 is cooled by the carbon dioxide flowing past.
[0038] A gap exists between the rotor 6 and the stator 7 . The inner partial flow 4 flows through this gap between the rotor 6 and the stator 7 . In order to reduce friction losses, a free-floating axially mounted sleeve 8 can be inserted into the gap. The inner partial flow 4 is guided through between the rotor 6 and the floating sleeve 8 and between the sleeve 8 and the stator 7 , and in so doing removes heat. As the gaps between the sleeve 8 and the rotor 6 and between the sleeve 8 and the stator 7 are very small, a pressure loss arises which must be considered when designing the turbocompressor.
[0039] The outer partial flow 4 is fed past between the stator 7 and a static component 9 . The static component 9 is an inner support structure. The outer partial flow 4 cools the stator 7 . It is fed along the winding heads and the laminated core. In order to set the ratio between the two partial flows 3 , 4 , a throttle is integrated into the path of the outer partial flow 4 . A split of 97% outer partial flow 4 to 3% inner partial flow 3 has proven particularly advantageous. A 3% proportion of the inner partial flow allows the rotor 6 to be cooled to approx. 50° C.
[0040] The stator 7 is attached to the inner support structure. The inner support structure, for its part, is secured to the main flange 10 of the housing 2 .
[0041] The magnet of the rotor 6 is shrunk into a shaft 11 . In addition, three radial impellers 12 are secured on the shaft 11 . The shaft 11 is mounted with two radial gas bearings 13 and one axial gas bearing 14 . The turbocompressor is entirely oil-free.
[0042] Both partial flows 3 , 4 are united before entering the first compressor stage. The carbon dioxide is compressed in the three compressor stages to a pressure of 90 bar and exits at the discharge opening 19 . According to the invention, the discharge opening 19 is arranged centrally in the axial direction with respect to the axis of rotation of the shaft 11 . At the outlet, the carbon dioxide is in a supercritical state.
[0043] FIG. 3 shows the three radial impellers 12 arranged one behind another. The radial impellers 12 are arranged in parallel next to one another on the shaft 11 . In this case they are closed radial impellers. The carbon dioxide enters inlet openings 15 of the radial impellers 12 in the axial direction and exits in the radial direction from the outlet openings 16 . The carbon dioxide is compressed from left to right as seen in the depiction and hence always in the same axial direction.
[0044] FIG. 4 shows an axial section through the three compressor stages. After the radial impeller 12 , the carbon dioxide passes into a diffuser 17 and then flows on into a return duct 18 . Kinetic energy is imparted to the carbon dioxide in the radial impellers 12 and is converted to pressure energy in the diffusers 17 . The return ducts 18 feed the carbon dioxide to the next compressor stage. According to the invention, in the final compressor stage, the carbon dioxide flows first through a radial impeller 12 , then through a diffuser 17 and then through a return duct 18 which feeds the carbon dioxide directly to the discharge opening 19 which is arranged centrally in the axial direction with respect to the axis of rotation of the shaft 11 .
[0045] FIG. 5 shows the housing 2 of the turbocompressor. The housing 2 is embodied as a cylindrical pressure vessel. According to the invention, the housing 2 is split vertically. It consists of the main flange 10 , an intake-side part 20 and a discharge-side part 21 . The discharge-side part 21 consists of a flange ring 22 , a tubular piece 23 and a torispherical head 24 which are welded together to form one component. At the center of the torispherical head 24 is a connection piece 25 which projects outward in the axial direction and has a duct as discharge opening 19 for the carbon dioxide.
[0046] The intake-side part 20 of the housing 2 has a torispherical head 26 . The intake opening 1 is introduced into the housing 2 at the center of the torispherical head 26 . The intake opening 1 and the discharge opening 19 lie on an axis A A′ which passes axially through the center of the cylindrical housing 2 .
[0047] The main flange 10 supports all the integrated elements and provides space for leadthroughs such as the electrical supply or temperature probe. The main flange 10 serves as a basic element for the assembly as all integrated elements are secured to the main flange 10 .
[0048] FIGS. 6 a and 6 b show the construction of the radial impellers 12 . FIG. 6 a shows the assembled state with cover disk 27 . The cover disk 27 is not shown in FIG. 6 b in order to show the inside of the radial impeller 12 . The blades 28 of the radial impeller 12 are formed on a support body 29 . The cover disk 27 is manufactured separately and is positioned on the support body 29 having its blades 28 . The cover disk 27 is connected over the entire surface to the upper edges of the blades 28 and therefore rotates, when the turbocompressor is in operation, at the same rotational speed as the support body 29 having its blades 28 . The radial impellers 12 are pushed onto the shaft 11 via the hub 30 .
[0049] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof. | A radial turbocompressor having at least two compressor stages is provided. A motor is co-axially located on a shaft with radial impellers of the compressor stages, and the motor and the compressor stages are arranged in a common, vertically-split housing. The medium to be compressed enters the housing through an intake opening in the housing, flows past and/or through the motor, and then is compressed in the compressor stages. The medium leaves the housing through an discharge opening that is arranged co-axially with the shaft, thereby minimizing axial forces in the turbocompressor. | 5 |
FIELD OF THE INVENTION
The present invention relates generally to clamping mechanisms and more particularly concerns a clamping mechanism for frictionally engaging and securing together the components of a gear drive such as a gear ring, a gearwheel and a shaft.
BACKGROUND OF THE INVENTION
A problem frequently recurring in engineering is to releasably interconnect rotationally symmetrical parts. Clamping connections are frequently used for this purpose based on frictional transmission of forces. In such cases, spring forces, fluid pressure devices, or simple screw connections, apply a clamping force which, by acting on friction surfaces, ensures that the two parts are connected so as to rotate with one another. Very high forces are necessary in some cases to maintain the connection and secure the relative position of the two parts. Consequently, ordinary clamping elements are unsuitable or else the requirements that the clamping elements must satisfy are of such high specification that in some cases uneconomical connecting elements have to be used.
In printing engineering it is known, for example, to dispose double gearwheels in the transmission line of sheet-fed rotary presses so that sub-units of the press can be displaced relative to one another. In a double gearwheel of this kind, a gearwheel ring is fitted on a main gearwheel and is clamped fast there by means of clamping elements. The latter must ensure that the relative position between the gearwheel ring and the main gearwheel is maintained even under maximum stress. In some cases the clamping connection is in the form of a simple pressure connection, the friction surfaces between the gearwheel ring and the main gearwheel being used for the force transmission. Typically, the peripheral forces are applied by normal forces of appropriate value. For this purpose, strong springs and a corresponding number of clamping screws are required.
One approach to such an arrangement is described in DE-A1 38 20 026. As shown in this references, the gear ring is coupled to the main gearwheel via a connection in the form of a disc clutch in order to provide a non-positive connection between a fixed gearwheel and a movable gearwheel on a cylinder of a turn-over mechanism in a sheet-fed rotary press. The clutch discs are mounted at the end face of the main gearwheel and clutch discs are also provided concentrically thereof on the gearwheel ring and engage in the spaces between the clutch discs on the main gearwheel. In the region of the overlap, a clamp ring is fitted on the clutch discs and can be clamped relative to the main gearwheel. As a result, the clutch discs are clamped together and the gearwheel ring is frictionally connected to the main gearwheel.
Unfortunately, the entire arrangement of the foregoing reference makes the construction of the double gearwheel relatively complex. Also, there is no safeguard that the frictional forces will be uniformly distributed over the entire periphery. In addition, the construction is expensive due to the large number of parts.
A mechanism for deforming a gearwheel is known from DE-C1 3834429. This reference describes a gearwheel whose hub can be deformed by tensioning elements in order to change the diameter. However, it is not possible to secure the gearwheel with this mechanism.
It is the primary aim of the present invention to provide a clamping mechanism which enables a reliable and secure frictional connection to be achieved between relatively rotatable components of a gear drive.
A related and important object is to provide such a frictional clamping mechanism which achieves a secure connection in a relatively simple manner with greatly reduced forces.
It is also an object of the invention to provide a frictional clamping mechanism that employs only a few parts that may be made relatively economically.
In accordance with the present invention, a clamping mechanism is provided for securing together two radially adjacent concentric components of a gear drive, such components including, for example, a toothed gear ring, a gearwheel, a hub and a shaft. An annular recess is formed in the gear drive component and defines at least one circumferential and one radial wall. A substantially conically shaped convex clamping disc having a plurality of circumferentially spaced apertures is disposed in the annular recess. A plurality of tensioning bolts cooperate with the apertures in the clamping disc and threaded bores in the annular recess to compress the clamping disc and urge its peripheral edges radially into frictional engagement with the concentric gear drive components and axially into frictional engagement with the radial wall of the annular recess.
A particularly advantageous feature of the clamping mechanism of the present invention is that there is not just one friction surface in the axial direction, but also at least one other one directed radially to the gearwheel. Depending on the specific arrangement, two radially directed friction surfaces may be provided, thus enabling the transmissible torques to be additionally increased. Furthermore, the release forces required for tensioning elements of this kind are reduced in comparison with purely screw or spring connections. The conical arrangement of the tensioning element results in differences in clamping forces at the periphery of the gearwheel being substantially uniform. Assembly and removal of the gearwheels or gearwheel rings are also greatly simplified. The mechanism can be used with a direct or indirect action. In addition, the radial tensioning surfaces may optionally be used separately or else the radial and axial tensioning surfaces can be used jointly. Finally, in combination with the tensioning effect, it is also possible to deform the gearwheel ring to correct production errors.
These and other features and advantages of the invention will be more readily apparent upon reading the following description of the preferred embodiments of the invention and upon reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary axial section through a double gearwheel of a sheet-fed printing press drive;
FIG. 2 is a similar axial section through a gearwheel with a gearwheel ring fitted radially thereon;
FIG. 3 is a fragmentary axial section through a gearwheel fixed to a shaft according to the invention; and,
FIG. 4 is a plan view of a tensioning element of the type illustrated in FIGS. 1 and 3.
While the invention will be described and disclosed in connection with certain preferred embodiments and procedures, it is not intended to limit the invention to those specific embodiments. Rather it is intended to cover all such alternative embodiments and modifications as fall within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings, FIG. 1 shows how a main gearwheel .1I in the drive of a sheet-fed printing press can have connected to it a gearwheel ring 2 to form a double gearwheel. In this embodiment, the inner periphery of the gearwheel ring 2 is mounted on a collar 3 of the main gearwheel 1. In accordance with the invention, the gearwheel ring 2 is clamped to the main gearwheel 1 by friction forces applied by a tensioning element in the form of a clamping disc 4. The clamping disc 4 is in the form of a conical annular disc having an outwardly convex shape with an annular rise 5 at the center, the inner and outer peripheral edges of the annular disc being in the form of rings 4.1 and 4.2. As shown here, the clamping disc 4 is disposed coaxially to the main gearwheel 1 in an annular recess 3.1 having an inner circumferential wall and an outwardly extending radial wall. The outer periphery of the clamping disc is disposed in an annular groove 3.2 having radial and circumferentially oriented walls in the gear ring 2. The clamping disc 4 has a friction surface R1 at its inner periphery, another friction surface R2 at its outer periphery and additional friction surfaces R3 and R4 at one end face.
In the illustrated embodiment, tensioning bolts or screws 6 engage the tensioning element 4 in the area of the annular rise 5 of the cone. The tensioning bolts or screws 6 pass through circumferentially spaced apertures in the annular disc 4 and are screwed into internally threaded axial bores disposed in circumferentially spaced relation in the main gearwheel 1. The tensioning force is thus adjusted by way of the prestressing of the tensioning screws 6. As a result, the clamping disc 4 is pressed apart at the annular rise 5 so that it is urged radially in the inward or outward direction and in so doing is pressed tightly with its inner peripheral edges at R1 and R3 frictionally engaging, respectively, against the circumferential and radial walls of the annular recess 3.1 of the main gearwheel 1, and the outer peripheral edges at R2 and R4 frictionally engaging, respectively, against the circumferential and radial walls of the annular groove 3.2 of the gear ring 2. In these conditions the tensioning element or clamping ring 4 is wedged by the peripheral edge rings 4.1 and 4.2 in the tensioning surfaces on the main gearwheel 1 and the gearwheel ring 2. In the case of manual tensioning, the tensioning screws 6 have to be retensioned as necessary or, to release the gearwheel ring 2, have to be released. In each case the clamping disc 4 is subject to deformation with a corresponding increase or reduction in the diameter of the clamping disc.
It will be appreciated, of course, that the foregoing arrangement is also suitable for automatic tensioning. A release force can be exerted on the tensioning screws in the main gearwheel by way of an auxiliary element. A spring assembly, for example, may be provided for each tensioning screw in order to generate a counteracting force. The clamping force of the spring assembly on the tensioning element may be reduced for releasing the coupling and the tensioning element is relieved of tension. Under these conditions, the frictional connections at the outer ring of the tensioning element are also relieved and the gearwheel ring can be turned relative to the main gearwheel. Such a spring assembly arrangement is also advantageous in order to achieve a peripherally more uniform action of the tensioning element. This type of an arrangement also contributes towards keeping the actuating forces low and is particularly important for automated releasing operation.
A clamping connection of the foregoing kind can also be employed for fixing gearwheels on a cylinder journal or shaft. In that case, tensioning elements can be provided on both sides of the gearwheel. Any inaccuracies in the manufacture of gearwheels can be obviated by an arrangement using a corresponding plurality of tensioning screws at the periphery.
Turning now to an alternative embodiment of FIG. 2, a gearwheel ring 7 is fixed on a gearwheel flange 8 mounted on a shaft 13. Between the flange 8 and the gearwheel ring 7 a tensioning element 10 is provided laterally on a collar 9 coaxially to the gearwheel. As shown here the tensioning element 10 consists of just a ring 10.1 in the form of an inclined annular disc. Tensioning screws 11 anchored in circumferentially spaced bores in the flange 8 engage in the raised outer periphery 10.2. Peripheral securement is provided by retaining screws 12.
In accordance with this embodiment of the invention, the tensioning element 10 serves to secure the gearwheel ring 7 relative to the shaft 13. When the tensioning screws 11 are adjusted, the tensioning element 10 presses by its outer periphery 10.2 to a varying degree against the inner periphery of the gearwheel ring 7 and bears by the ring 10.1 internally and at the end face against the collar 9. To improve the adjustment, the outer periphery 10.2 can be formed as an axially convex annular surface. Alternatively, it is also possible to achieve simultaneous clamping and tensioning, if the tensioning element 10 is constructed, as in FIG. 1 as a two-sided annular disc and is arranged to engage in a corresponding annular recess on the gearwheel ring 7.
Pursuant to further embodiments of the invention, FIG. 3 shows two variants for securing a gearwheel on a shaft. As shown here, the gearwheel 14 is mounted by its hub 15 on a shaft 16. Two tensioning elements 17 and 18 are provided in the area of the hub 15 to clamp the gearwheel 14 on the shaft 16 and coaxially to the shaft. One tensioning element 17 is mounted in a recess 19 at the edge of the shaft bore in the gearwheel 14. It is formed as a conical annular disc having at each periphery a generally rectangularly shaped edge ring. Tensioning screws 20 are disposed in the region of the annular rise 21 of the annular disc and are threadedly anchored in the hub 15. The other tensioning element 18 shown in FIG. 3 is mounted in an annular recess 22 between the hub 15 and the body of the gearwheel 14. The hub terminates in a wide axially extending and relatively easily deformable foot 23. The tensioning element 18 is held by tensioning screws 30. Thus when the tensioning screws 20 and 30 are tightened, the gearwheel 14 is either directly or indirectly clamped on the shaft 16 via the foot 23 by means of the tensioning elements 17 and 18 as a result of elastic deformation.
Turning now to FIG. 4, a plan view of a tensioning element 24 is shown which may correspond to the tensioning elements 4, 17 and 18 in the exemplified embodiments described above in connection with FIGS. 1 and 3. It consists of a conical annular disc 25 terminating in an annular rise 26. In cross-section, therefore, it is generally outwardly convex somewhat in the shape of a roof, as shown in FIGS. 1 and 3. Circumferentially spaced apertures 27 are disposed in the region of the rise 26 and the annular disc 25 is bounded by outer and inner peripheral rings 28 and 29, respectively, of substantially rectangular cross-section. The tensioning element 24 is subjected to elastic deformation in the direction of the broken lines A and B by tensioning with tensioning screws (not shown here) in the apertures 27. It will also be understood that to facilitate deformation, either the outer ring 28 and/or the inner ring 29 of the tensioning element 24 may optionally be provided with radial slots. | A clamping mechanism for frictionally securing together two radially adjacent concentric components of a gear drive wherein an annular clamping disc having concentric inner and outer peripheral edges and a substantially conically shaped convex portion between the edges is partially disposed in an annular recess in one of the gear drive components. Force applying means, such as tensioning bolts, cooperate with circumferentially spaced apertures in the convex portion of the clamping disc and threaded bores in the component to urge the peripheral edges of the clamping disc into frictional engagement with wall portions of the annular recess and with a concentric surface of the radially adjacent gear drive component. | 5 |
FIELD OF INVENTION
[0001] The present invention relates to handheld devices for removing frost and snow from windshields and window panes of automobiles, trucks and other types of vehicles. The invention more particularly relates to handheld power operated mechanical devices to scrape frost from surfaces on automobiles and other vehicles.
BACKGROUND OF INVENTION
[0002] The most common snow removal devices found in automobiles are simple hand-held devices having a scraper blade and/or brush on one or both ends of the handle. Generally, the hand-held devices tend to require a great deal of effort and are extremely slow in removing frost and snow, especially when the snow has hardened. To make it a little easier to remove frost and ice, heating devices generally comprising of an electrical coil and battery to power the heater element have been disclosed. The heating devices are of only slightly greater efficiency, since their power output is low and takes a long time to melt the snow on the window pane or windshield. These have been disclosed in U.S. Pat. No. 5,973,294—“Heated windshield scraper device” awarded to Michael Schatt et al., U.S. Pat. No. 5,357,646—“Heated ice scraper” awarded to David Kim, U.S. Pat. No. 4,930,176—“Combination heated scraper and brush” awarded to Gideon Gelman, 20050061793—“Ice scraper” submitted by Williams J. Deane III (patent pending), 20040148810—“Ice and snow remover” submitted by Bill Hsu (patent pending) and 20040021575—“Methods and apparatus for melting snow and ice on a vehicle” submitted by John Jeffrey Oskorep (patent pending). Because the power output of the heater is limited while the heat required to melt snow on the windshield is large, the task of removing snow from a windshield is still likely to take a considerable amount of time.
[0003] To overcome the above limitations, David Weissberger obtained a patent with U.S. Pat. No. 3,935,425 for a “Mechanized electrically heated windshield cleaner”. In this, the scraper head is moved back and forth in a straight line by a motor. At the same time, the tip of the scraper is heated using a heating element. Though this is a much better solution than the ones cited above, it also suffers from certain drawbacks. First, since it takes a relatively long time to melt snow, the heating element is ineffective. Second, since the scraper head does not have a guide, optimal scraping angle and pressure cannot be applied to the scraper head for it to do a good job. Third, since the scraper blade is not enclosed, it is not safe to work with an exposed blade. Fourth, the back and forth motion is not very efficient since the blade tip goes from zero velocity to a maximum velocity and back to zero velocity before changing its direction of movement. Fifth, to transfer a rotational motion of the motor to linear motion, a few linkages have to be used which increases the cost of manufacture. Sixth, the scraped snow will accumulate just ahead of the scraper blade and should be brushed off by the user.
SUMMARY OF INVENTION
[0004] The primary objective of the present invention is to come up with a powered mechanical scraper that overcomes the above mentioned deficiencies so as to minimize the driver's exposure to the elements and help the driver do a better job of cleaning the front and rear windshields and window panes.
[0005] Another objective of the present invention is to make the manufacture of the improved mechanized scraper cost effective for the manufacturer to adopt it.
[0006] The foregoing objectives are attained by having a multi-blade circular scraper (so called because of the circular motion of the scraper blades) attached to one end of a motor shaft and having a protective housing around the circular scraper so that the scraping edge of the scraper and the bottom rim of the housing are at the same level. Thus the driver can apply optimal pressure on the scraper housing without damaging the scraper blades. Also, the driver is protected from injury from the rotating blades by the protective housing around the blades. The multi-blade design hastens the process of snow and frost removal from the automotive windshield and window panes.
[0007] To aid in the fast removal of the scraped snow from the work area, a fan is attached to the other end of the motor shaft, away from the scraper blades. The air blown by the fan is directed at the work area and the scraped snow is blown away from the work area through vents in the circular housing.
[0008] To make it convenient for the driver to use the unit, the scraper is powered by rechargeable battery that can be charged using the car power outlet.
[0009] In the ensuing description, frost, ice and snow are used interchangeably.
[0010] 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.
[0011] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is the side view of a preferred embodiment of the mechanized scraper of the present invention with the inside components visible. In this the fan draws air from the top.
[0013] FIG. 2 is the side view of another preferred embodiment of the mechanized scraper of the present invention with the inside components visible. In this embodiment also, the fan draws air from the top.
[0014] FIG. 3 is the top view of the preferred embodiment of the present invention displaying the screened opening for air inlet for the fan.
[0015] FIG. 4 is an assembly view of the components of a preferred embodiment of the present invention. Here a double shaft electric motor is used to rotate the fan blades and the scraper blades.
[0016] FIG. 5 is an assembly view of the components of another preferred embodiment of the present invention. Here a single shaft electric motor is used to rotate the fan blades and the scraper blades.
[0017] FIG. 6 is an assembly view of the components of yet another preferred embodiment of the present invention. Here a single shaft electric motor is used to rotate the fan blades and the scraper blades.
[0018] FIG. 7 is the side view of yet another preferred embodiment of the mechanized scraper of the present invention with the inside components visible. In this the fan draws air from the side instead of the top. Here two single shaft electric motors are used, one for the fan assembly and the other for the scraper blade unit.
[0019] FIG. 8 is a perspective view of a preferred embodiment of the present invention for the scraper blade assembly where the blades are straight and where the blades do not meet at the center.
[0020] FIG. 9 is a perspective view of another preferred embodiment of the present invention for the scraper blade assembly where the blades are straight and where the blades meet at the center.
[0021] FIG. 10 is a perspective view of another preferred embodiment of the present invention for the scraper blade assembly where the blades are curved and where the blades do not meet at the center.
[0022] FIG. 11 is a perspective view of another preferred embodiment of the present invention for the scraper blade assembly where the blades are curved and where the blades meet at the center.
[0023] The numbering is kept consistent across FIG. 1 through FIG. 11 for clarity. Hence like reference numerals designate like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 refers to a preferred embodiment of the present invention of a mechanical scraper unit with its internal parts exposed. The whole unit is generally referred to as 1 . Unit 1 has a cylindrical housing 2 with a handle 7 . The housing 2 has the scraper assembly 6 of the present invention while handle 7 houses a switch 3 to turn the unit on and off, a rechargeable power source 4 and electrical contacts 5 to charge the rechargeable power source. A partition 10 between the cylindrical housing 2 and the handle 7 prevents air from flowing into the handle. An axial flow fan is used in this embodiment. Thus the full force of the air blown by the axial fan is directed at the work surface where the scraper is acting to remove frost and snow. All around the circumference of the housing 2 , adjacent to the scraper blades are vents, marked 8 , through which air drawn in by the fan blows out scraped snow. The bottom edge of the housing is marked 9 in the figure.
[0025] FIG. 2 is another preferred embodiment of the present invention of a mechanical scraper unit with its internal parts exposed. It is the same as FIG. 1 , except for the shape of the housing 2 . The housing has a nozzle shape, which ensures that the air velocity is increased as the air reaches the work surface where the scraper is acting to remove frost and snow.
[0026] FIG. 3 is the top view of the present invention with a screen 11 above the mechanical assembly mentioned in FIG. 1 . Air is drawn in through the screen by the fan to blow out the scraped snow.
[0027] FIG. 4 is a preferred embodiment of the scraper assembly 6 . It consists of a motor 14 , with a double shaft protruding out axially on both sides of the motor. The shaft protruding out on one side of the motor is numbered 13 while the shaft protruding out on the other side of the motor is numbered 15 . An axial flow fan blade assembly 12 is mounted on shaft 13 of the motor. A reduction gear assembly 16 is mounted on shaft 15 of the motor. The scraper blade assembly, generally referred to as 22 , is connected to the output shaft 17 of the reduction gear assembly 16 . The scraper blade assembly has one or more blades 20 and a ring 18 that is attached to the radial ends of the blades for added strength. The ring 18 is attached to the blades 20 such that the bottom edge 19 of the ring is above the scraping edges 21 of the blades. The scraping edges 21 of all the blades are on the same plane.
[0028] FIG. 5 is another preferred embodiment of the scraper assembly 6 . It consists of a motor 14 , with a single shaft 13 protruding out axially on one side of the motor. The motor is mounted such that the shaft faces the air inlet 11 . A gear, 24 , is mounted on shaft 13 of the motor. An axial flow fan blade assembly 12 is mounted on shaft 13 , on top of gear 24 . Two gears, 25 and 27 , are mounted on the two ends of a shaft, 26 . This gear assembly is mounted such that gear 25 engages with gear 24 . The axis of the shaft is parallel to the axis of the motor. Another gear 28 engages with gear 27 . Gear 28 is mounted on one end of a shaft 29 , whose axis is the same as the axis of the motor. A reduction gear assembly 16 is mounted on the free end of shaft 29 . The scraper blade assembly, generally referred to as 22 , is connected to the output shaft 17 of the reduction gear assembly 16 . The scraper blade assembly has one or more blades 20 and a ring 18 that is attached to the radial ends of the blades for added strength. The ring 18 is attached to the blades 20 such that the bottom edge 19 of the ring is above the scraping edges 21 of the blades. The scraping edges 21 of all the blades are on the same plane.
[0029] FIG. 6 is another preferred embodiment of the scraper assembly 6 . It consists of a motor 14 , with a single shaft 13 protruding out axially on one side of the motor. In this embodiment, the motor shaft is away from the air inlet 11 of FIG. 3 . An axial flow fan blade assembly 12 is mounted on shaft 13 . A reduction gear assembly 16 is also mounted on shaft 13 , below the fan blade assembly. The scraper blade assembly, generally referred to as 22 , is connected to the output shaft 17 of the reduction gear assembly 16 . The scraper blade assembly has one or more blades 20 and a ring 18 that is attached to the radial ends of the blades for added strength. The ring 18 is attached to the blades 20 such that the bottom edge 19 of the ring is above the scraping edges 21 of the blades. The scraping edges 21 of all the blades are on the same plane.
[0030] FIG. 7 is another preferred embodiment of the present invention of a mechanical scraper unit with its internal parts exposed. Unlike the unit in FIG. 1 and FIG. 2 , the fan used here is a radial flow fan. The air is drawn in from the side of the cylindrical housing 2 and blown down along the axis of the scraper assembly. Here, two motors are used, one for the fan assembly and another for the scraper assembly.
[0031] FIG. 8 is a perspective view of the preferred embodiment of the scraper blade assembly 22 . It shows a center shaft 23 , to the circumference of which a plurality of straight blades, 20 , are attached. To increase the rigidity of these blades, the other ends of this plurality of blades are attached to the inner circumference of a ring 18 . The bottom end of the shaft does not extend to the scraping edges 21 of the blades. Hence, when the blades scrape the snow, the shaft does not touch the glass. In this embodiment, the blades do not meet at the center.
[0032] FIG. 9 is a perspective view of another preferred embodiment of the scraper blade assembly 22 . It is the same as FIG. 8 except that the blades meet at the center.
[0033] FIG. 10 is a perspective view of another preferred embodiment of the scraper blade assembly 22 . It is similar to FIG. 8 except that the blades are curved. Since the blades are curved, it requires less power than the straight blades to scrape snow. In this embodiment, the blades do not meet at the center. The arrow shows the direction of rotation of the blades.
[0034] FIG. 11 is a perspective view of another preferred embodiment of the scraper blade assembly 22 . It is the same as FIG. 10 except that the blades meet at the center.
[0035] When the user wants to scrape frost off the windshield, he/she turns the switch 3 on while holding the scraper unit in such a way that the scraper blades touch the frost. In the case of the double shafted motor, this causes the motor shafts 13 and 15 to rotate, thus rotating the fan blades as well as the scraper blades. In the case of the single shafted motor, turning on switch 3 causes the motor shaft 13 to rotate, thus rotating the scraper blades as well as the fan blades. The scraper blades make a circular motion and scrape the snow. At the same time, the fan blades draw air in through the air inlet 11 and blow it on the scraped snow. The snow and air are forced out through vents 8 adjacent to the scraper blades. Once all the glass surfaces such as the front and rear windshield and window panes have been cleared of frost, the user can power off the unit and replace it in the car power outlet to charge the scraper unit for future use. | A handheld mechanized windshield scraper with a built-in blower to remove snow, ice and other material from a motor vehicle windshield and window panes. The blower tube is tapered to increase air velocity. A plurality of scraper blades is rotatably mounted on a shaft away from the blower to scrape material off of the windshield. Vents are provided in the casing for air to blow the scraped snow out from the work area. The unit can have a built-in power source or can be connected directly to the power outlet of the automobile. | 1 |
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to techniques for formation resistivity logging using induction tools. More particularly, the invention relates to methods and systems for correcting borehole effects in resistivity measurements obtained with induction tools that include transverse or triaxial arrays.
[0003] 2. Background Art
[0004] Induction tools are used in the oil and gas industry to determine the resistivity of earth formations surrounding a borehole. Induction tools work by using a transmitting coil (transmitter) to set up an alternating magnetic field in the earth formations. This alternating magnetic field induces eddy currents in the formations. One or more receiving coils (receivers), disposed at a distance from the transmitter, are used to detect the current flowing in the earth formation. The magnitudes of the received signals are proportional to the formation conductivity. Therefore, formation conductivities may be derived from the received signals.
[0005] However, heterogeneities in the formation complicate the derivation of formation conductivity from the received signals. The most prevalent complication that affects the derivation of formation conductivity from the received signals arises from the presence of conductive fluids in the borehole surrounding the induction instrument. This is referred to generally as the borehole effects. Often, the fluids in the borehole (drilling mud) are made very saline, thus conductive, as part of the drilling practice. The conductive drilling muds can contribute a significant proportion of the received signals and, therefore, should be carefully removed.
[0006] Recently, transverse induction instruments have been developed for investigating the resistivities of formations with anisotropy, dipping planes, faults, or fractures. These transverse induction instruments have transmitting and receiving coils arranged such that the magnetic moments of the transmitter and/or receiver coils are perpendicular to the axis of the borehole. It is well known that the borehole effects of transverse coil arrangements are very large when the instrument is moved eccentrically in the borehole in the direction perpendicular to the coil magnetic moments. See e.g., Moran and Gianzero, “ Effects of Formation Anisotropy on Resistivity Logging Measurements ,” Geophysics, 44, 1266-1286 (1979).
[0007] The cause of the eccentricity effect of transverse coils is disclosed in U.S. Pat. No. 6,573,722, issued to Rosthal et al. This patent teaches a method for mitigating the eccentric borehole effects of an induction tool. Specifically, this patent discloses tool designs in which an induction tool includes a conductive member in its insulating sleeve or the induction tool includes a conductive tool body. These conductive parts greatly reduce the borehole effects of such an instrument, but does not remove all of the effects. Further correction would be necessary to completely remove the borehole effects of a transverse induction instrument.
[0008] U.S. Pat. No. 5,041,975, issued to Minerbo et al. discloses a method for correcting borehole effects of array induction instruments. This method uses the data from the 4 shortest arrays of an array induction tool, along with approximate measurements of the hole size and the borehole fluid conductivity, to solve for 2 parameters in a 4-parameter borehole-formation model. The model consists of a borehole having a radius r drilled in a homogeneous formation of conductivity □ f . The borehole fluid has a conductivity □ m , and the induction tool is located at a distance (standoff) s from the borehole wall. A fast forward model consists of a large table built from a number of cases over appropriate ranges of the 4 parameters. An inversion process minimizes the penalty function E, which is the sum of the squares of a weighted difference between the measured response and predicted response, as shown in Equation (1):
E ( σ _ ? ) = ∑ j = 1 4 σ ? - σ ? ( σ m , σ _ f , r , s ) 2 ? .
? indicates text missing or illegible when filed ( 1 )
[0009] In this equation Equation
σmax
is the modeled conductivity from the j-th array with the given parameters □ m , □ f , r, and s. When E is minimized, the associated parameters □ m , □ f , r, and s are used to compute the borehole correction for all the arrays.
[0010] While effective methods are available for correcting borehole effects for axial arrays, transverse array instruments present special problems. The sensitivity of induction arrays with moments perpendicular to the axis of the borehole to eccentricity is very different depending on whether the eccentricity is in the direction of the magnetic moment or perpendicular to the magnetic moment. U.S. Pat. No. 6,556,015 issued to Omeragic et al. describes methods of reducing the effect of the borehole on induction measurements with transverse coils through mechanical or electromagnetic rotation of the tool about its axis. However, there still exists a need for better methods for borehole effect corrections that can be used with transverse array instruments.
SUMMARY OF INVENTION
[0011] One aspect of the invention relates to methods for modeling borehole effects of an induction tool having a plurality of arrays that include at least one transverse array. A method in accordance with one embodiment of the invention includes selecting a formation-borehole model having a set of parameters, wherein the set of parameters comprises a direction of tool eccentering; determining initial values for the set of parameters; computing expected responses for a selected set of arrays from the plurality of arrays of the induction tool, wherein the computing is based on the formation-borehole model; comparing the expected responses with actual responses for the selected set of arrays; adjusting values of the set of parameters, if a difference between the expected responses and the actual responses is no less than a predetermined criterion; repeating the computing, the comparing, and the adjusting, until the difference between the expected responses and the actual responses is less than the predetermined criterion; determining the borehole effects from final values of the set of parameters.
[0012] Another aspect of the invention relates to systems for borehole effects of an induction tool having a plurality of arrays that include at least one transverse array. A system in accordance with one embodiment of the invention includes a processor and a memory, wherein the memory stores a program having instructions for: selecting a formation-borehole model having a set of parameters, wherein the set of parameters comprises a direction of tool eccentering; determining initial values for the set of parameters; computing expected responses for a selected set of arrays from the plurality of arrays of the induction tool, wherein the computing is based on the formation-borehole model; comparing the expected responses with actual responses for the selected set of arrays; adjusting values of the set of parameters, if a difference between the expected responses and the actual responses is no less than a predetermined criterion; repeating the computing, the comparing, and the adjusting, until the difference between the expected responses and the actual responses is less than the predetermined criterion; determining the borehole effects from final values of the set of parameters.
[0013] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIGS. 1 a and 1 b , respectively, illustrate tool eccentering of a transverse array and the asymmetric current distribution that causes the undesired borehole effects.
[0015] FIG. 2 shows a comparison of the eccentricity effects in two different directions of a transverse induction array in an insulating sleeve.
[0016] FIG. 3 shows residual eccentricity effects in two different directions of a transverse induction array on a conducting mandrel.
[0017] FIG. 4 illustrates a layout of a triaxial induction array showing the tool coordinate system.
[0018] FIG. 5 shows residual eccentricity effects of cross-couplings of a triaxial induction tool.
[0019] FIG. 6 shows a parametric model for borehole effect correction of a triaxial induction array in accordance with one embodiment of the invention.
[0020] FIG. 7 shows a multi-array triaxial induction tool having a triaxial transmitter, 3 axial receiver arrays, and 6 triaxial receiver arrays.
[0021] FIG. 8 shows a method for borehole correction in accordance with one embodiment of the invention.
[0022] FIGS. 9 a , 9 b , and 9 c illustrate the application of a method of the invention for correcting borehole effects.
[0023] FIG. 10 illustrates a prior art computer that may be used with embodiments of the invention.
DETAILED DESCRIPTION
[0024] Embodiments of the invention relate to methods and systems for correcting borehole effects in induction tools having transverse or triaxial antennas. Methods of the invention are applicable to both induction tools and propagation tools. Because the distinction between an induction tool and a propagation tool is not germane to this invention, the term “induction tool” is used in this description to include both the induction and propagation tools. Similarly, borehole effects and tool eccentering effects (or eccentricity effects) are used interchangeably in this description because the distinction between them is not germane. One of ordinary skill would appreciate that conductivity is an inverse of the resistivity, and, therefore, any reference to “conductivity” in this description is intended to include its inverse, the “resistivity,” and vice versa.
[0025] As noted above, induction arrays with magnetic moments perpendicular (i.e., transverse) to the axis of the borehole are more sensitive to the borehole effects. In addition, the sensitivity of a transverse coil to eccentricity is very different depending on whether the eccentricity is in the direction of the magnetic moment or perpendicular to the magnetic moment. In this description, a transverse array is used in a broad sense to include any array having a transverse component in its magnetic moment. For example, an array having a tilted coil (i.e., a coil not parallel or perpendicular to the axis of the tool) will have a transverse component in its magnetic moment and, therefore, may be referred to as a transverse array in this description. Similarly, a triaxial array is a subset of a transverse array.
[0026] FIG. 1 a illustrates that a logging tool may have its transverse or tilted magnetic dipole (TMD) antenna located at the center (shown as 20 ) of the borehole 13 or eccentered in a parallel direction (shown as 22 ) or a perpendicular direction (shown as 21 ). The parallel or perpendicular direction is with respect to the direction of the magnetic dipole of the antenna. Parallel eccentering 22 produces eddy currents up and down the borehole. However, due to the symmetry, no net current flows up or down the borehole. Thus, a tool having its TMD antenna eccentered in the parallel direction 22 does not produce undesired effects more than a tool having its TMD antenna perfectly at the center of the borehole 20 does. In contrast, a tool having its TMD antenna eccentered in the perpendicular direction 21 induces eddy currents to flow up and down the borehole, but without the symmetry to cancel out the up and down currents. As a result, perpendicular eccentering 21 gives rise to significant borehole currents 23 , as shown in FIG. 1 b . The current flow in the formation is also asymmetric in this case. The asymmetric current distribution produces a strong signal in a receiver 24 disposed on the resistivity instrument 10 .
[0027] The perpendicular eccentering 21 and parallel eccentering 22 shown in FIG. 1 a illustrate the extremes of tool displacements from the center of the borehole 20 . In a typical case, the eccentering would likely lie between these two extremes, i.e., eccentering in a direction that is a combination of both the x and y directions.
[0028] FIG. 2 shows that the eccentricity effects of an induction tool. The curves shown are for a tool having an insulating sleeve disposed in a 7.9″ diameter borehole. The conductivity of the mud (σ m ) is 5.1 S/m and the conductivity of the formation (σ f ) is 0.061 S/m. As shown, curve xx represents eccentering of the tool in the x-direction (the direction of the magnetic moment). This situation is shown as 22 in FIG. 1 a . As noted above, eccentering in the direction parallel with the direction of the magnetic moment produces minimal borehole effects, Thus, curve xx is essentially flat as a function of the eccentricity. In contrast, curve yy, which depicts eccentering in the direction perpendicular to the direction of the magnetic moment (shown as 21 in FIG. 1 a ), is very sensitive to the eccentering distances. As shown in FIG. 2 , the eccentering effects in the direction perpendicular to the direction of the magnetic moment of the coil (curve yy) can be up to two orders of magnitude stronger than that in the direction parallel with the magnetic moment (curve xx).
[0029] The unusual sensitivity to the eccentricity in the direction perpendicular to the magnetic moment can be reduced by inclusion of a conductive member in the insulating sleeve, as disclosed in U.S. Pat. No. 6,573,722 issued to Rosthal, et al. However, inclusion of a conductive member in the insulating sleeve does not completely eliminate the differential effects. As shown in FIG. 3 , the eccentric effects in the direction perpendicular to the direction of the magnetic moment (curve yy) are still more significant than the eccentricity effects in the direction parallel with the direction of the magnetic moment (curve xx), although they are on the same order of magnitude. The curves shown in FIG. 3 are for a tool having a conductive mandrel disposed in a 7.9″ diameter borehole. The conductivity of the mud (σ m ) is 5.1 S/m and the conductivity of the formation (σ f ) is 0.061 S/m.
[0030] The most common arrangement for an induction tool having transverse coils is a fully triaxial array, as shown in FIG. 4 . FIG. 4 shows that the triaxial array consists of a triad of transmitters mounted orthogonally and a triad of receivers at a spacing L m mounted in substantially the same orthogonal directions as the transmitter coils. In FIG. 4 , the triad transmitters are shown as having magnetic moments, M x T , M y T , M z T , while the triad receivers are shown as having magnetic moments, M x M , M y M , M z M . Such an arrangement is called a two-triad array. Such an array is not useful in an actual logging operation because the direct couplings between the i-th transmitter and the i-th receiver (i=1, 2, 3) are much larger than any signal from the formation. The adverse effects from the mutual couplings can be mitigated, in a way similar to a conventional axial induction array, by mounting a triad of orthogonal receivers between the main receiver triad and the transmitter triad. This additional triad is referred to as a balancing triad (or a bucking triad). In FIG. 4 , the balancing triad is shown at a distance L B from the transmitter triad, as having magnetic moments
M x B , M y B ′ , M z B .
The number of turns in each coil of a balancing triad is adjusted so that, in air, the sum of the voltages detected by the main and balancing triads is zero. That is,
=0, (2)
where
V m l
is the voltage induced in the i-th main receiver by the i-th transmitter, and
V b l
is the voltage induced on the i-th balancing receiver by the same i-th transmitter.
[0031] The array shown in FIG. 4 produces nine couplings. The voltages can be considered as a matrix V:
V = [ V ? V ? V ? V ? V ? V ? V ? V ? V ? ] ,
? indicates text missing or illegible when filed ( 3 )
where v ij is the voltage detected by the i-th receiver from energizing the i-th transmitter. Depending on the directions of eccentricity, each or some of these couplings may have associated eccentricity effects (borehole effects) that would need to be corrected.
[0032] As an example, FIG. 5 shows the eccentricity effects of the xz, zx, yz, and zy couplings. The curves shown are for a tool having a conductive sonde body, disposed in a 7.9″ diameter borehole, and eccentered in the x direction. The conductivity of the mud (σ m ) is 5.1 S/m and the conductivity of the formation (σ f ) is 0.061 S/m. When the tool is displaced along the x direction in a circular cylindrical borehole, there are only five non-zero couplings, i.e., the matrix V has the form
V = [ V ? 0 V ? 0 V ? 0 V ? 0 V ? ]
? indicates text missing or illegible when filed ( 4 )
[0033] Among the four couplings shown in FIG. 5 , only xz and zx couplings are influenced by the borehole effects, because yz and zy couplings produce substantially zero signals, as illustrated in Equation (4). On the other hand, if the eccentering is in the y direction, then the yz and zy couplings will have substantial borehole effects, while xz and zx couplings will have no borehole effects. In practice, the tool is likely eccentered in a direction that is a combination of the x and y directions. Therefore, these four couplings are likely all influenced by the borehole effects. The relative magnitudes of the borehole effects among these four couplings depend on the actual eccentering direction. Therefore, it should be possible to derive the eccentering direction of the tool from the borehole effects in these four couplings. A method for deriving the eccentering direction from these measurements will be described later. In addition, these couplings may be included in an inversion process to enable more sensitive determination of the eccentering direction.
[0034] The borehole/eccentricity effect of each coupling of a triaxial array can be described as a parametric model in a similar manner to the axial coils described above. However, the model for the triaxial arrays will have additional parameters. First, because the borehole effects depend on the direction of tool eccentering, the model should include the standoff and its direction relative to the tool x-axis (or y-axis). In addition, the transverse arrays are sensitive to formation anisotropy. Therefore, according to some embodiments of the invention, the formation conductivity in the model may include anisotropic components. In this case, the formation-borehole model for calibrating a triaxial array includes six parameters: □ m , □ fh , □ fh , r, s, and the eccentering direction n. A formation-bore-hole model including these six parameters are illustrated in FIG. 6 . One of ordinary skill in the art would appreciate that a formation model for use in the calibration of a triaxial array may include more or less than six parameters. For example, a formation-borehole model for calibrating a triaxial array may further include dipping angles, if the formation includes dipping planes or the borehole is a deviated hole. Similarly, the formation-borehole model for calibrating a triaxial array may include five parameters: □ m , □ f , r, s, and the eccentering direction □—if the formation is isotropic.
[0035] A preferred triaxial induction tool my include a triaxial transmitter, several axial receiver arrays, and at least one triaxial receiver array. For example, FIG. 7 illustrates one embodiment of a triaxial induction tool having a triaxial transmitter, 3 axial receiver arrays, and 6 triaxial receiver arrays. The data from each of the 3 axial arrays include the following couplings:
[ V ? V ? V ? ]
? indicates text missing or illegible when filed ( 5 )
[0036] Each of the triaxial arrays on a tool shown in FIG. 7 has 9 couplings as shown in Equation (6).
[ V ? V ? V ? V ? V ? V ? V ? V ? V ? ]
? indicates text missing or illegible when filed ( 6 )
[0037] Each or some of these couplings may include borehole/eccentering effects, which would need to be removed before deriving formation resistivity from these measurements.
[0038] As noted above, a method for correcting borehole effects for an axial array is disclosed in U.S. Pat. No. 5,041,975 issued to Minerbo and Miles. This patent is assigned to the assignee of the present invention and is incorporated by reference in its entirety. According to the method disclosed in this patent, a formation model includes four parameters: mud conductivity (□ m ), borehole radius (r), standoff distance (s), and the formation conductivity (□ f ). Often, the mud conductivity (□ m ) and the standoff (s) are known. According to a method disclosed in this patent, measurements from the four shortest arrays are used in an inversion process to derive the parameters of the formation model.
[0039] If this method is extended to a triaxial tool shown in FIG. 7 , data from the 4 shortest arrays may be used to solve for borehole parameters. Alternatively, data from other couplings may be selected for inclusion in the computation based on desired properties. For example, the xz and yz couplings are quite directional, and, therefore, their inclusion in an inversion scheme can provide useful information for determining the direction of eccentering (□). A method for determining the direction of eccentering (□) will be described later. Similarly, the xx and yy couplings have good sensitivity to the vertical conductivity (□ fv ) and, therefore, they may be included in the inversion to provide a better estimate of the vertical conductivity (□ fv ).
[0040] FIG. 8 shows a method 80 in accordance with one embodiment of the invention. First, a formation-borehole model (e.g., that shown in FIG. 6 ) is selected and the initial estimates of the parameters are determined (step 81 ). Some of the parameters may be known from other measurements. For example, the mud conductivity (□ m ) may be obtained from a mud sensor, and the borehole radius (r) may be obtained from caliper measurements.
[0041] The method then computes array responses in the selected formation-borehole model (step 82 ). The computation may be a direct solution of Maxwell's equations in this model, or it may be a table built from such a solution. A table would be built to include a sufficient range of all 6 parameters. In addition, interpolation techniques, such as the Akima interpolation, may be used to estimate responses that fall between discrete parameter values. Reference is made to the paper by Hiroshi Akima: “ Bivariate Interpolation and Smooth Surface Fitting Based on Local Procedures ,” (Algorithm 474), Commun. ACM 17(1): 26-31 (1974).
[0042] An inversion technique is then used to compare and match the computed results with the experimental results (step 83 ). This step may use any inversion technique known in the art. The inversion finds a match between the computed responses and the actual tool responses by looking for parameters in the formation-borehole model that produce a minimum in the penalty function E T or reduce the penalty function E T below a selected criterion (c). Various penalty functions may be used for this purpose. Equation (7) shows a least square penalty function that may be used with embodiments of the invention.
E T ( σ _ ? , σ _ ? ) = ∑ ? = 1 4 ∑ ? = 1 ? σ ? - σ ? ( σ m , σ _ ? , σ _ ? , r , ? s ) 2 ? ,
? indicates text missing or illegible when filed ( 7 )
where E T is the triaxial penalty function, □ m is the borehole (mud) conductivity; □ fv and □ fh are the vertical and horizontal conductivities of the formation, respectively; r is the borehole radius; s is the standoff; n is the eccentering direction relative to the tool coordinate system; □ is the index for the directional couplings; and j is the index for the arrays. e ij is the weight appropriate for each coupling. N is either 3 or 9, depending on whether the receiver is axial or triaxial. Note that the penalty function E T in Equation (7) sums over 4 arrays (j=1-4), because data from 4 shortest arrays are used. One of ordinary skill in the art would appreciate that the precise number of summation depends on the measurement data used. As noted above, the hole size (i.e., borehole radius, r) and borehole (mud) conductivity (□ m ) can be measured independently. For example, the borehole radius (r) may be determined using a caliper and the mud conductivity (□ m ) determined with a mud resistivity sensor. The other four variables (□ fh , □ fh , s, and □) can then be determined using the inversion technique and the data from the 4 shortest arrays.
[0043] The inversion process optimizes the parameters to produce a minimum penalty function E T or to produce a penalty function E T below a selected criterion (ε). The optimization process (step 87 ) is iterative: if the penalty function E T is not below the selected criterion ε, then the parameters are adjusted (step 84 ); the responses of the forward model is re-computed (step 82 ); and the computed responses are compared with the determined responses (step 83 ). These steps (84, 82, 83) are repeated until the penalty function E T is at a minimum or is below the selected criterion ε.
[0044] Once the penalty function E T is at a minimum or is below the selected criterion c, then the estimated (optimized) parameters may be output and used to correct borehole effects in other arrays (step 85 ). Specifically, the optimized borehole parameters are used to compute borehole effects (in terms of conductivity) for each coupling in the remaining arrays. Then, the borehole effects are subtracted from the actual measurements (or conductivity derived from these measurements) from each of these couplings/arrays to yield the corrected measurements (or cond uctivities).
[0045] These optimized parameters may also be used to compute other parameters, such as tool standoffs in the x and y directions (step 86 ).
[0046] FIG. 8 illustrates a method in accordance with one embodiment of the invention. One of ordinary skill in the art would appreciate that modifications of this method are possible without departing from the scope of the invention. For example, other penalty functions may be used. In addition, more or fewer parameters may be determined from other measurements and used in the computation described above. For example, the direction (angle α) of tool eccentering may be determined from the measurement data, which will be described later, and used in the computation to reduce the number of parameters to be estimated from the inversion.
[0047] Application of a method (shown in FIG. 8 ) in accordance with one embodiment of the invention is illustrated in FIG. 9 . This example is based on an isotropic formation, i.e., □ fv =□ fh . The graphs shown are receiver responses for a series of formation-borehole models with varying □ fh and □ m . FIG. 9 a shows the expected homogeneous formation responses of an array in a 5.0 inch borehole. The tool standoff is 0.125 inch and the direction of the eccentering is 67.5° from the x-direction. FIG. 9 b shows actual tool responses of this array in the borehole under the same conditions. A comparison between FIG. 9 a and FIG. 9 b shows that borehole effects are quite significant when the mud is conductive. FIG. 9 c shows the corrected tool responses obtained by correcting the borehole effects in the responses shown in FIG. 9 b . The borehole effect correction was performed using a method similar to that shown in FIG. 8 , except that the formation model is isotropic (□ fv =□ fh ). The corrected data shown in FIG. 9 c is substantially the same as the expected responses for the homogeneous formation shown in FIG. 9 a , attesting to the effectiveness of the borehole effect correction in accordance with embodiments of the invention.
[0048] As noted above, the tool eccentering angle α may be independently determined, leaving only three unknowns to be determined in Equation (7). The direction of the displacement of the tool in the borehole can be determined from the measured triaxial data as follows. The matrix of voltages in Equation (3) can be converted into apparent conductivities:
σ _ _ appt = [ σ ? σ ? σ ? σ ? σ ? σ ? σ ? σ ? σ ? ]
? indicates text missing or illegible when filed ( 8 )
by dividing the voltages V ij with the sensitivity factors K ij , i.e.,
σ ij =V ij /K ij
. The diagonal sensitivity factors K xx , K yy , K zz are chosen so that, in a homogeneous isotropic medium with a low conductivity, the diagonal conductivities □ xx =□ yy =□ zz =□ hom , where □ hom is the conductivity of the homogeneous formation, i.e.,
σ _ appt = [ σ ? 0 0 0 σ ? 0 0 0 σ ? ] .
? indicates text missing or illegible when filed ( 9 )
[0049] Similarly, the off-diagonal sensitivity factors may be chosen to simplify rotation transformations, for example, K yx =K xy and K xx =K yy . For the special case of a rotation around the z axis, the rotation matrix is
R = [ cos ϕ - sin ϕ 0 sin ϕ cos ϕ 0 0 0 1 ] ( 10 )
where □ is the rotation angle. The effect of this rotation on the apparent conductivity matrix may be written as:
σ _ _ appt ′ = R σ _ _ appt R T . ( 11 )
[0050] When the tool is eccentered in the x direction in a circular borehole, the apparent conductivity matrix has five non-zero components that can be computed by modeling:
σ _ appt = [ σ ? 0 σ ? 0 σ ? 0 σ ? 0 σ ? ] .
? indicates text missing or illegible when filed ( 12 )
[0051] In the rotated coordinate system, this becomes:
? = R [ ? 0 ? 0 ? 0 ? 0 ? ] R T = [ σ ? cos 2 ϕ + σ ? sin 2 ϕ ( σ ? - σ ? ) sin ϕcos ϕ σ ? cos ϕ ( σ ? - σ ? ) sin ϕcos ϕ σ ? sin 2 ϕ + σ ? cos 2 ϕ σ ? sin ϕ σ ? cos ϕ σ ? sin ϕ σ ? ] .
? indicates text missing or illegible when filed ( 13 )
[0052] Estimates of the angle □ can be obtained by comparing the matrix of measurements from each triaxial receiver pair to the theoretical matrix in Equation (13). For example, comparison between □ xz and □ yz gives:
ϕ ? = - arctan ( σ ? σ ? ) .
? indicates text missing or illegible when filed ( 14 )
[0053] Similarly, comparison between □ zx and □ zy gives:
ϕ ? = - arctan ( σ ? σ ? )
? indicates text missing or illegible when filed ( 15 )
[0054] Note that measured conductivity components are used in Equations (14-15). Other estimates can be obtained from □ xx , □ xy , □ yx , and □ yy , in a similar fashion:
ϕ ? = arctan { σ ? - σ ? ± ( σ ? - σ ? ) 2 + 4 σ ? σ ? 2 σ ? } ,
? indicates text missing or illegible when filed ( 16 )
and
ϕ ? = arctan { σ ? - σ ? ± ( σ ? - σ ? ) 2 + 4 σ ? σ ? 2 σ ? } .
? indicates text missing or illegible when filed ( 17 )
[0055] Equations (16) and (17) give four angles, but only two of these are physically distinct. Note that □ in Equations ( 10 , 13 - 17 ) is the same as □ in Figure ( 6 ). To take into account data from several triaxial receiver pairs, a least squares minimization may be performed on all □ ι values obtained in Equations (14-17) to determine the angle □. After the angle □ is determined, the borehole corrections may then be applied to the data using the computed values in Equation (12). The corrected matrix of apparent conductivities is then rotated back to the original tool coordinates, as follows:
σ _ _ corr = R T σ _ _ corr ′ R . ( 18 )
[0056] Some embodiments of the invention relate to systems for performing the above-described methods for correcting borehole effects in triaxial arrays. A system in accordance with embodiments of the invention may be implemented on a stand alone computer or a downhole computer that is included on a tool. FIG. 10 shows a general purpose computer that may be used with embodiments of the invention.
[0057] As shown in FIG. 10 , a general computer system may include a main unit 160 , a display 162 and input devices such as a keyboard 168 and a mouse. The main unit 160 may include a central processor unit 164 , a permanent memory (e.g., a hard disk) 163 and a random access memory 166 . The memory 163 may include a program that includes instructions for performing the methods of the invention. A program may be embodied on any computer retrievable medium, such as a hard disk, a diskette, a CD-ROM, or any other medium known or yet to be developed. The programming may be accomplished with any programming language and the instructions may be in a form of a source codes that may need compilation before the computer can execute the instructions or in a compiled (binary) or semi-compiled codes. The precise form and medium the program is on are not germane to the invention and should not limit the scope of the invention.
[0058] 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 herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A method for modeling borehole effects of a transverse array induction tool includes selecting a formation-borehole model having a set of parameters, wherein the set of parameters comprises a direction of tool eccentering; determining initial values for the set of parameters; computing expected responses for a selected set of arrays from the plurality of arrays of the induction tool, wherein the computing is based on the formation-borehole model; comparing the expected responses with actual responses for the selected set of arrays; adjusting values of the set of parameters, if a difference between the expected responses and the actual responses is no less than a predetermined criterion; repeating the computing, the comparing, and the adjusting, until the difference between the expected responses and the actual responses is less than the predetermined criterion; determining the borehole effects from final values of the set of parameters. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to pipe protectors, especially those suited to use on oil well drill pipe and pipe strings for the protection of such pipe and the casing in which the pipe operates.
In the drilling of oil-, gas-, and water wells, it is common practice to place resilient collars at spaced locations along the drill pipe string. Such collars are called pipe protectors. They serve as buffers to cushion impacts and reduce wear between the drill string and the surrounding casing as the drill string is rotated or run into or out of the well.
U.S. Pat. No. 3,652,138, issued Mar. 28, 1972, to Charles H. Collett, for "Self-Locking Snap-on Collar for Oil Well Operations", discloses pipe collars useful in themselves as pipe or rod protectors, or useful as stop collars for longitudinally positioning a relatively rotatable protector on a pipe.
SUMMARY OF THE INVENTION
A principal object of the invention is to provide a drill pipe and casing protector that is quick and easy to install upon and remove from a drill pipe or the like.
A further object is to provide a protector that tenaciously grips the pipe upon which it is installed, and effectively resists forces that tend to dislodge it.
Another object is to provide a protector that minimizes the erosive and corrosive action of the drilling fluid upon the pipe as the fluid flows around the protector in the annulus between the pipe and the casing.
The foregoing and other aims, objects and advantages of the invention are achieved in a pipe protector for use on oil well drill pipe and the like comprising: a longitudinally split, generally cylindrical band of spring steel; a first plate of strong, tough steel; first means affixing said first plate to one end of said band with a portion of said first plate extending beyond said one end; a second plate of strong tough steel; second means affixing said second plate to the other end of said band with a portion of said second plate extending beyond said other end; radially projecting, longitudinally extended, discrete locking means of strong, tough metal affixed to said portion of said first plate and having a width in the circumferential direction substantially greater than its thickness in the radial direction; said portion of said second plate providing longitudinally extended, radial locking recess means adapted to receive said locking means; said band being adapted to be circumferentially contracted to move said plates relative to one another and to slide said locking means along a surface of said second plate until said locking means snaps into said locking recess means and portions of the opposed circumferential surfaces of said plates are in overlapping relation; said locking means and said locking recess means having generally radial faces adapted to abut each other when said locking means is disposed in said locking recess means to prevent circumferential expansion of said band; a longitudinally split, annular collar of pliant, elastic material substantially encasing said band and said plates, the material of said collar terminating short of said overlapping portions of the opposed circumferential surfaces of said plates to expose said portions; and means engageable by an implement for contracting and locking said collar in tightly gripping disposition around a pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings:
FIG. 1 is a vertical elevational view, with parts broken away, of a section of a drilling string disposed within a casing, a pipe protector being mounted on the drilling string;
FIG. 2 is an enlarged perspective view of a pipe protector in accordance with the invention and in its unlocked and relaxed condition;
FIG. 3 is a perspective view of an insert like that embedded in the elastomeric collar of the pipe protector of FIG. 2, the insert being unlocked and in relaxed condition;
FIG. 4 is a plan view, with parts broken away, of the pipe protector of FIGS. 2 and 3 partially contracted around a section of pipe preparatory to its being fully contracted and locked tightly on the pipe, the jaws of an installation tool being shown in operative position;
FIG. 5 is a view similar to FIG. 4, but showing the pipe protector tensioned into position on the pipe, the pipe tool jaws being omitted;
FIG. 6 is an enlarged fragmentary sectional view of the lock portion of the protector in locked condition;
FIG. 7 is a perspective view similar to that of FIG. 2 of another form of pipe protector in accordance with the invention;
FIG. 8 is a view similar to that of FIG. 3 of an insert as used in the pipe protector of FIG. 7;
FIG. 9 is a fragmentary, horizontal, medial sectional view of a portion of the pipe protector of FIG. 7 encircling a pipe and partially contracted and ready to be tightened into firm engagement with the pipe;
FIG. 10 is a view similar to that of FIG. 9, but showing the pipe protector tensioned about the pipe; and
FIG. 11 is an enlarged fragmentary sectional view of the lock portion of the protector of FIG. 7 in locked condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, particularly to FIG. 1, there is shown a section of well casing C. It will be understood that the casing typically is cemented into a well bore (not shown) extending down into the earth. A drilling string, designated by the general reference character D, is disposed inside the casing. The drilling string is formed of a number of sections of drill pipe, only two of which P 1 and P 2 are shown by way of illustration. The upper end of the lower pipe section P 1 is provided with the usual box coupling member M 1 , which has an internal, tapered female-threaded portion IT. The lower end of the immediately superjacent pipe section P 2 has a pin coupling member M 2 , complementary to the box coupling member. The pin coupling member has an external, tapered male-threaded portion ET that is screwed into the complementary threads of the box member to couple the pipe sections to each other. It will be understood that similar pipe sections above and below those shown in FIG. 1 are coupled into the string by means of pin-and-box joints like those shown.
At the bottom of the drilling string there is mounted a drilling bit (not shown). The drilling string is rotated by a conventional rotary table drive (not shown) located at the earth's surface, to thereby turn the drilling bit and drill the well deeper into the earth. Drilling mud is circulated by mud pumps in the usual way down through the bore B of the drill string, out through openings in the drill bit, and up through the annulus A between the drill string D and the casing C.
A pipe protector PP constructed in accordance with the invention, is shown as mounted on the drill pipe section P 2 , preferably close to the pipe joint M 1 M 2 . Such protector has a pliant, elastic outer body of wear-resistant rubber or the like that cushions impacts against the inner walls of the casing as the drill string is rotated and/or moved axially in the casing. Thus, it protects the drill string, especially the joint portions thereof, and the interior of the casing from wear and damage which, without the protector, would result from direct metal-to-metal contact. Protectors may be mounted on each section of pipe in the drill string to obtain maximum protection against damage.
One form or embodiment of the protector of the present invention is generally designated by the reference characters PP in FIGS. 2, 4 and 5. This protector has a longitudinally split collar or body 10 made of a pliant, elastic material, such as rubber, preferably synthetic rubber compounded to have a long service life in the environment of oil or gas wells.
The collar is shown in its unlocked and relaxed condition in FIG. 2. An insert, designated by the general reference numeral 11 (See FIG. 3) is embedded in or encased by the collar 10. A generally longitudinal slit through the collar 10 and insert 11 provides a vertical opening 12 through the wall of the protector which may be expanded to allow the protector to be passed over a pipe for subsequent contraction into tight engagement with the pipe.
The portion 13 of the collar 10 that is disposed radially outwardly of the inset 11 provides a relatively thick cushion of elastomeric material for absorbing impact shocks. This portion has a generally cylindrical vertical, outer surface. The top surface 14 of the casing tapers inwardly as it rises at an angle of about 45° to the vertical, and merges into a narrow annular top end surface 15 surrounding a central, cylindrical, vertical opening 16. The bottom 17 of the casing is tapered as it descends at an angle of about 45° to the vertical to meet a narrow annular bottom end surface 18, similar to the top annular end surface 15.
The portion 13' of the collar 10 that is disposed radially inwardly of the insert 11 is provided with a plurality of longitudinally extending, circumferentially spaced grooves 19. These grooves terminate at their upper ends below the top end surface 15 of the casing, and at their lower ends above the bottom end surface 18.
Referring to FIG. 3, it is seen that the insert 11 is a composite structure having a back band 21 in the form of a section of a right cylinder. This back band is fabricated from good quality spring steel. It is seen in FIG. 3 in its relaxed condition. It has opposed, longitudinally extending edges 22 and 23 that are circumferentially spaced from one another. Upper and lower rows of bonding holes 24 are provided in the back band.
A rectangular female lock plate 25 is affixed to the inner side of one end of the back band by rivets 26, the rivets also fastening a reinforcing strip 27 to the outer side of this end of the back band. An aperture 28 to allow insertion of an installation tool jaw is provided in the back band adjacent to the central portion of the reinforcing strip and the central portion of the riveted edge of the plate 25.
Near the center of the lock plate 25 there is provided a female locking recess 29 which, in the modification shown in FIG. 3, has the form of a longitudinal slot, rounded at its upper and lower ends.
It will be seen that the female lock plate 25 extends from its riveted edge towards the edge 23 of the back band and terminates at its free longitudinal edge in an inturned ramp portion 31, which serves a purpose to be explained hereinafter.
A male lock plate 32 is fastened to the other end of the back band 21 by a longitudinal row of rivets 33. The rivets also are used to fasten a reinforcing strip 34 to the inside surface of said other end of the band. The strip 34 extends from top to bottom of the back band.
Affixed to the free end of the male lock plate 32 by rivets 35 is a longitudinally disposed male lock member in the form of a lock bar 36. A portion of the male lock plate is broken away in FIG. 3 merely for the purpose of showing one end of the lock bar, the latter being rectangular in shape.
Adjacent to the center of the riveted edge of the male lock plate and to the center of the reinforcing strip 34, a second tool jaw aperture 37 is provided in the back band 21.
Turning now to FIG. 4, the pipe protector PP is shown as wrapped around a pipe P 2 and partially closed thereon. The closing or tensioning of the protector is effected by an installation tool, the jaws 38, 39 of which are moved towards one another to contract the protector. Such installation tools are well known and need not be further described. In order that the tool jaws may exert force against the reinforced portions 41, 42 of the insert 11, jaw recesses 43 and 44 are provided in the rubber collar. These recesses extend at least partially through the apertures 37, 28 in the back band 21, but stop short of the radially inner surface of the inner portion 13' of the collar. As shown, a small thickness of rubber may lie between the jaws and the reinforced portions 41, 42.
In FIG. 4, it is seen that the lock bar 36 and rivets 35 are in contact with the inturned or ramp portion 31 of the female lock plate 25. As the protector is further contracted into its fully closed position, the rivets 35 ride up the ramp portion and over the surface of the female lock plate until the lock bar 36 snaps into the female locking recess or slot 29. The spring action of the back band 21 and the forces exerted by the jaws 38, 39 hold the rivets 35 in sliding contact with the female lock plate and snap the lock bar into the locking recess.
FIG. 5 shows the pipe protector fully tensioned about the pipe P 2 and locked thereon. It is seen that the lock bar 36 is disposed in the complementary lock slot 29, and that portions of the opposed circumferential surfaces of the female lock plate 25 and the male lock plate 32 are in overlapping relation. The joint between the ends of the protector may be described as lap joint.
Moving to FIG. 6, there is shown an enlarged fragment of the lock portion of the protector with the complementary lock elements interengaged. It is seen that the lock bar has a longitudinal face 45 that abuts a complementary face 46 on the female locking means 29. These faces are in abutment for the entire height of the lock bar 36. The faces 45 and 46 are disposed at an acute angle to an intersecting radius of the protector, the angle referably being in the range of 15° to 20°, more or less, with respect to such radius. The face 45 is disposed radially inwardly of the face 46, to thereby oppose radial disengagement of the lock bar from the slot. The face 45 of the lock bar may be said to slope outwardly and towards the free end 47 of the radially outer overlapping plate 32, and the face 46 in the slot 29 may be said to slope outwardly and away from the free end 31 of the radially inner overlapping plate 25.
When the locking parts are engaged, there is very little bending moment applied to the lock bar 36. The circumferential forces applied to the lock bar are transferred to the rivets primarily as shear forces. Thus, a very strong lock arrangement is provided by a lock bar whose circumferential extent is several times greater than its radial extent.
It will be understood that, if desired, the lock bar could be affixed to the radially inner plate member and project outwardly into a complementary slot in the radially outer plate member. Moreover, a ramp, such as the ramp portion 31 could be provided on the free end of the radially outer overlapping plate, if desired.
The lock plates 25 and 32 may be fabricated of any suitable material such as a strong and tough grade of alloy steel. The rivets may be made of a malleable steel alloy. The pliant, elastic casing is applied and bonded to the insert by molding and curing methods common to rubber manufacturing processes. In this regard, the rubber compound on the radially inner side of the insert is united to that on the radially outer side of the insert through the previously described bonding holes 24. As seen in FIG. 1, the elastomeric material of the collar 10 is continuous over the top edge and under the bottom edge of the insert.
The tapered top and bottom ends of the protector provide for smooth flow of drilling fluids and cuttings over and past the protector, thereby minimizing corrosion and erosion of the drill pipe.
The previously described axial grooves 19 provide contact pads 48 (See FIG. 1) on the inner surface of the protector, which pads are compressed when the protector is locked on the drill pipe and which serve to prevent axial and rotational movement of the protector on the drill pipe while permitting easy installation of the protector. Rubber that is displaced when the pads are compressed moves circumferentially, thereby circumferentially narrowing the grooves 19. As pointed out hereinbefore, the grooves 19 stop short of the top and bottom of the protector, whereby, drilling fluid is prevented from flowing between the protector and the drill pipe. If drilling fluid were permitted to flow between the protector and the drill pipe, the latter would be eroded and corroded by the fluid.
The insert 11 of the hereinbefore described protector PP functions extremely well as a component of the protector. The spring back band 21 functions primarily as the required spring element. The lock plates 25 and 32, the lock bar 36 and the reinforcing strips 27 and 34, being made of strong and tough alloy steel, are ideally suited to their respective purposes. The lock bar is not subject to high bending moments. Provision is made for applying the jaws of the installation tool to reinforced and strong areas of the insert. The ramp portion 31 facilitates installation of the protector on a pipe, and its curvature adds strength and rigidity to the free end of the female lock plate 25.
The protector may be removed from a pipe by driving a wedge between the overlapping plates 25 and 32 to force them apart. After the lock bar 36 has been withdrawn from the locking recess 29, the protector is allowed to expand to its relaxed condition. The protector is then removed from around the pipe.
The pipe protector of the invention shown in FIGS. 7 to 10 is designated by the general reference character PP'. It is like the pipe protector PP shown in FIGS. 1 to 6 and described hereinbefore, save only that it has a different form of lock means. Therefore, it is not necessary to describe in detail the numerous elements that are common to both pipe protectors. It is pointed out that the pipe protector PP' has an elastomeric collar 110 that encases a composite insert 111.
The collar 110 is provided with longitudinal grooves 119 spaced circumferentially around the central opening 116 to define the longitudinally extending contact pads 148 between successive grooves. The exterior configuration of the collar 110 is like that of the previously described collar 10.
As shown to advantage in FIG. 8, the insert 111 has a back band 121 of spring steel having bonding holes 124 therethrough and apertures 128 and 137 to accept the jaws of an installation tool. A female clip or lock plate 125 and a male clip or lock plate 132 are affixed to opposite ends of the back band by elements that are the same as the corresponding elements of the previously described pipe protector. Female locking recess means in the form of vertically spaced circular holes 129 are provided in the female lock plate. Complementary male lock means, in the form of vertically arranged pins designated by the general reference numeral 136 are provided on the male lock plate 132.
Referring to FIG. 9, which shows the pipe protector PP' partially tightened about the pipe P' 2 ' , the pins 136 are illustrated as being engaged with the ramp portion 131 of the female lock plate 125. As the ends of the protector are moved into their fully closed position, the pins slide circumferentially over the radially outer surface of the female lock plate 125. When the pins become aligned with the holes 129, they snap into these holes, and the parts assume the positions shown in FIG. 10, wherein the pins 136 are shown as received in the holes 129, and portions of the male and female lock plates are in contact.
Turning now to FIG. 11, which shows, in section, the lock portion of the protector PP', the male lock plate 132 is seen to have an upset portion 151 which provides a circular depression 152 in the radially inner surface of the male lock plate. A hole 153 is provided in the center of the upset portion. The pin 136 is, in effect, a rivet having an upset head 154, a shank 155 that is fitted in the hole 153, a flange 156, and a distal portion 157. The distal portion is flared from the region of the flange to the free end of the pin and, thus, takes the shape of a truncated cone. The edge 158 of the hole 129 that receives the distal portion of the pin is beveled at an angle corresponding to the angle of flare of the distal portion to provide a reentrant surface that is engaged by the distal portion. With tension on the elements of the lock portion when the protector is locked around a pipe, the pin is firmly held in the female recess 129 against radial displacement therefrom. The angle of the beveled parts may be from about 15° to 25°, more or less, to a radius of the protector that intersects the beveled parts.
To remove the protector PP' from the pipe P' 2 , a wedge is driven between the female lock plate 125 and the male lock plate 132 to force these lock plates apart. After the pins 136 have been withdrawn from the holes 129, the protector is allowed to expand to its relaxed condition. The ends of the protector are then manually separated, and the protector is removed from around the pipe.
The pipe protector PP', as well as the previously described pipe protector PP, can be easily removed from the pipe by but one workman, who drives the wedge and then manually removes the protector from the pipe. It is not necessary to have a second workman manipulate an installation tool to relieve the tension from the lock parts of the protector, as is required with some heretofore known types of pipe protectors, while the one workman withdraws a lock pin from opposed loops carried by the ends of the metallic insert of the protector.
The insert 111 of the protector PP' serves purposes and provides advantages similar to those set forth hereinbefore with reference to the insert 11 of the first-described form of the invention.
Although two forms of pipe protector according to the invention have been shown and described, it will be understood that such forms are illustrative of the invention and not limitative thereof. Various modifications may be made in the pipe protectors of the invention without departing from its spirit and scope as defined in the claims, which should be interpreted as broadly as the prior art will permit.
As required by the Patent Statutes, the applicant has set forth herein the best mode contemplated by him for carrying out his invention. | A drill pipe protector for use on drill pipe and the like having an outer pliant and resilient collar that envelops an insert of composite construction. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for measuring the thickness of a form document set in an impact printer, such as a dot line printer, and more particularly to a form thickness measuring device for measuring thickness of a continuous form consisting of a single or plural stacked sheets of paper.
2. Description of the Related Art
Conventional impact serial printers include a print head and a platen for supporting a print paper or a form document thereon. The gap between the print head and the platen is determined depending upon the thickness of the form document so that hammers mounted on the print head can make impressions of dots on the form supported on the platen.
It should be noted that not only a form with a single sheet of paper but also a form with plural stacked sheets of paper can be used in the impact printers.
Unlike impact serial printers, dot line printers print on form documents by striking hammers, which are mounted on a 13.6 inch width print head, against the forms with a relatively strong force. Therefore, the gap between the print head and the platen needs to be precisely determined depending upon the thickness of the form. Nevertheless, there has been no form thickness measuring device for use in the dot line printer, that is low in manufacturing cost, simple in construction, and easy to operate.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a thickness measuring device capable of measuring a thickness of a form having a variable thickness, which is low in cost and high in accuracy.
To achieve the above and other objects, there is provided a thickness measuring device including a substrate; a stepping motor supported on the substrate and having a rotor shaft forwardly and reversely rotatable about its own axis; a translating mechanism for translating rotations of the rotor shaft into a linear movement; a pressing block formed with a projection, the pressing block being coupled to the rotor shaft through the translating mechanism for moving the projection toward and away from an object to be measured supported on a supporting plate in accordance with forward and reverse rotations of the stepping motor; and a control unit for controlling the stepping motor to move the projection from a predetermined fixed position to the object and then to backwardly move the projection from the object to the predetermined fixed position, and for computing a thickness of the object based on an actual amount of rotations of the stepping motor detected when the projection is moved a one-way distance between the predetermined fixed position and the object.
The control unit includes a non-volatile memory storing therein a reference amount of rotations of the stepping motor corresponding to a distance between the predetermined fixed position and the supporting plate, and computing means for computing the thickness of the object based on a subtracted amount of rotations obtained by subtracting the actual amount of rotations from the reference amount of rotations.
The control unit controls the stepping motor to move the projection from the predetermined fixed position to the supporting plate and then to backwardly move the projection from the object to the predetermined fixed position, and the control unit further includes detection means for detecting the reference amount of rotations of the stepping motor by moving the projection a one-way distance between the predetermined fixed position and the supporting plate. The detection means stores the reference amount of rotations in the non-volatile memory.
A first set of data including the actual amount of rotations and the reference amount of rotations is detected while rotating the stepping motor at a first pulse rate. The computing means further computes a first subtracted amount of rotations based on the first set of data. The control unit further includes comparison means for comparing the first subtracted amount of rotations with a first reference value, and determining means for determining that the object falls into a first range of thickness when the comparison means indicates that the first subtracted amount of rotations is less than the first reference value and that the object is out of the first range of thickness when the comparison means indicates that the first subtracted amount of rotations is equal to or greater than the first reference value.
A second set of data including the actual amount of rotations and the reference amount of rotations is detected while rotating said stepping motor at a second pulse rate lower than the first pulse rate. The computing means further computes a second subtracted amount of rotations based on the second set of data. The comparison means further compares the second subtracted amount of rotations with a second reference value greater than the first reference value, and the determining means further determines that the object falls into a second range of thickness when the comparison means indicates that the second subtracted amount of rotations is greater than the first reference value but less than the second reference value and that the object falls into a third range of thickness when said comparison means indicates that the second subtracted value is greater than the second reference value. The values in the first range of thickness is smaller than values in the second range of thickness, and the values in the second range of thickness is smaller than values in the third range of thickness.
When the determining means determines that the object falls into the third range of thickness, the control unit controls the stepping motor to rotate at a third pulse rate lower than the second pulse rate to compute the thickness of the object.
The control unit computes the thickness of the object based on the first subtracted amount of rotations when the determining means determines that the object falls into the first range of thickness. The control unit computes the thickness of the object based on the second subtracted amount of rotations when the determining means determines that the object falls into the second range of thickness.
A third set of data including the actual amount of rotations and the reference amount of rotations is detected while rotating the stepping motor at the third pulse rate lower than the second pulse rate. The computing means further computes a third subtracted amount of rotations based on the third set of data, and the control means computes the thickness of the object based on the third set of data.
In accordance with the thickness measurement of the invention, the thickness of the object can be obtained with high accuracy because the measured thickness is free from influence of resilient deformation of the supporting plate supporting the object to be measured.
According to another aspect of the present invention, there is provided a printer including a print head, a pin feed tractor, and a form thickness measuring device. The pin feed tractor feeds a form document past the print head, and has a tractor plate and a tractor cover arranged in parallel with each other to form a gap therebetween into which the form document is inserted.
The form thickness measuring device includes a substrate; a stepping motor supported on the substrate and having a rotor shaft forwardly and reversely rotatable about its own axis; a translating mechanism for translating rotations of the rotor shaft into a linear movement; a pressing block formed with a projection, the pressing block being coupled to the rotor shaft through the translating mechanism for moving the projection toward and away from the form document supported on the tractor cover through an opening formed on the tractor plate in accordance with forward and reverse rotations of the stepping motor; and a control unit. The control unit controls the stepping motor to move the projection from a predetermined fixed position to the form document and then to backwardly move the projection from the form document to the predetermined fixed position. The control unit further compute a thickness of the form document based on an actual amount of rotations of the stepping motor detected when the projection is moved a one-way distance between the predetermined fixed position and the form document.
The control unit further controls the stepping motor to move the projection from the predetermined fixed position to the tractor cover and then to backwardly move the projection from the tractor cover to the predetermined fixed position. The the control unit includes detection means for detecting a reference amount of rotations of the stepping motor by moving the projection a one-way distance between the predetermined fixed position and the tractor cover, a non-volatile memory, the detection means storing the reference amount of rotations in the non-volatile memory, and computing means for computing a difference between the actual amount of rotations and the reference amount of rotations, and computing the thickness of the form document based on the difference.
The control unit further comprises pulse rate changing means for changing a pulse rate of the rotations of the stepping motor, the pulse rate changing means changes the pulse rate based on the difference.
The pulse rate changing means decreases the pulse rate used for moving the projection from the predetermined fixed position to the form document and to the tractor cover when the difference is greater than a reference value.
According to another aspect of the present invention, there is provided a method of measuring the form thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view showing a form thickness measuring device according to an embodiment of the present invention;
FIG. 2 is a graphical representation showing pulse rate versus torque characteristic curves of a stepping motor used in the form thickness measuring device shown in FIG. 1;
FIG. 3 is an explanatory diagram illustrating measurement of a reference distance;
FIG. 4 is an explanatory diagram illustrating measurement of an actual distance;
FIG. 5 is a block diagram showing a control circuit and a driving circuit of the form thickness measuring device according to the embodiment of the present invention;
FIG. 6 is a time chart illustrating operations of the control circuit and the drive circuit according to the embodiment of the present invention;
FIG. 7 is another time chart illustrating operations of the control circuit and the drive circuit according to the embodiment of the present invention;
FIG. 8 is an explanatory diagram illustrating how to determine reference values used for discriminating forms;
FIG. 9 is a flowchart illustrating a form thickness measurement control program according to the embodiment of the present invention;
FIG. 10 is a flowchart illustrating another form thickness measurement control program according to the embodiment of the present invention;
FIGS. 11 ( a ) to 11 ( d ) are flowcharts illustrating sub-routines of the form thickness measurement control program according to the embodiment of the present invention; and
FIG. 12 is a perspective view showing a dot line printer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 1 shows a form thickness measuring device which is generally designated by reference numeral 100 .
The form thickness measuring device 100 includes a gap measuring sensor 10 , a stepping motor 1 , a stepping motor control circuit 20 to be described later with reference to FIG. 5, and a stepping motor drive circuit 30 also to be described later with reference to FIG. 5 .
The gap measuring sensor 10 includes a pressing block 4 , a projection 5 formed on the pressing block 4 , a guide member 9 , and a switch 16 which includes a washer 6 and contact points 15 A and 15 B. The stepping motor 1 is of a permanent magnet type and is relatively small in size with an outer diameter of 35 mm. The stepping motor 1 is supported on a substrate 7 . A male screw portion 2 ′ with a screw diameter of 3 mm and a screw pitch of 0.5 mm is formed in part of the rotor shaft 2 of the stepping motor 1 .
The pressing block 4 can be divided into three segments in terms of the outer size. The first segment is the smallest in outer size and has an end face confronting the substrate 7 . The second segment has a middle outer size and the third part has the largest outer size. A projection 5 is formed on the third segment of the pressing block 4 .
The first segment of the pressing block 4 is formed with a hole with which a nut 3 formed with a female screw portion is force-fitted. The female screw portion of the nut 3 threadingly engages the male screw portion 2 ′ of the rotor shaft 2 . The first segment of the pressing block 4 has a square outer shape, and the second and third segments of the pressing block 4 have a circular outer shape.
A pair of guide members 9 are disposed to contact two opposite outer surfaces of the first segment of the pressing block 4 . By virtue of the guide members 9 , the pressing block 4 is prevented from rotating with the rotor shaft 2 . The threading engagement between the rotor shaft 2 and the pressing block 4 translates the rotations of the rotor shaft 2 into linear movement of the pressing block 4 . That is, the pressing block 4 linearly moves in the direction in which the rotor shaft 2 extends. More specifically, when the stepping motor 1 rotates clockwise as viewed from the substrate 7 (hereinafter referred to as “forward rotation”), the pressing block 4 moves away from the substrate 7 whereas when the stepping motor 1 rotates counter-clockwise as viewed from the substrate 7 (hereinafter referred to as “reverse rotation”), the pressing block 4 moves toward the substrate 7 .
The washer 6 with gold plating on its surface is attached to the end face of the first segment of the pressing block 4 . On the other hand, a pair of contact points 15 A and 15 B with gold plating on their surfaces are mounted on the substrate 7 in positions confronting the washer 6 . The washer 6 and the pair of contact points 15 A and 15 B form the switch 16 . When the washer 6 is brought into contact with the contact points 15 A and 15 B, the switch 16 is rendered ON whereas when the washer 6 is isolated from the contact points 15 A and 15 B, the switch 16 is rendered OFF.
A cylindrical rubber curtain 11 is attached to the peripheral surface of the second segment of the pressing block 4 to enclose the first segment of the pressing block 4 . Free end of the rubber curtain 11 is urged against the substrate 7 to an extent that the rubber curtain 11 is slightly resiliently deformed. The washer 6 and contact points 15 A and 15 B are confined in a closed space defined by the cylindrical rubber curtain 11 , so that a malfunction of the switch does not occur due to dusts entering into the space.
The gap measuring sensor 10 with the above-described configuration is provided in a pin feed tractor. As shown in FIG. 12, the pin feed tractor 40 is provided for moving a continuous form 41 past a print head 43 while drivingly engaging with uniformly-spaced perforations 42 formed in the side margins of the continuous form 41 . The pin feed tractor 40 includes a tractor plate 12 and a tractor cover 13 arranged in parallel with each other with a gap of 0.7 mm therebetween into which the continuous form is inserted. As shown in FIG. 1, the tractor plate 12 and the tractor cover 13 are oriented in a direction perpendicular to the axial direction of the rotor shaft 2 . For simplifying the following description, the surface of the tractor plate 12 forming the gap with the tractor cover 13 will be referred to as “inner surface” of the tractor cover 12 . Also, the surface of the tractor cover 13 forming the gap with the tractor plate 12 will be referred to as “inner surface” of the tractor cover 13 .
The gap measuring sensor 10 is fixed to the tractor plate 12 with screws 14 . The tractor plate 12 is formed with a through-hole into which the projection 5 is inserted. The top end of the projection 5 faces the inner surface of the tractor cover 13 .
In accordance with forward and reverse rotations of the stepping motor 1 , the projection 5 moves toward and away from the tractor cover 13 . With two complete forward rotations of the rotor shaft 2 , the projection 5 moves 1.0 mm toward the inner surface of the tractor cover 13 . Conversely, with two complete reverse rotations of the rotor shaft 2 , the projection 5 moves 1.0 mm away from the inner surface of the tractor cover 13 . In this embodiment, when the washer 6 is in the reference position, the top end of the projection 5 is located at a position 0.3 mm down from the inner surface of the tractor plate 12 . Therefore, from this position, the top end of the projection 5 will be brought into contact with the inner surface of the tractor cover 13 with two forward rotations of the rotor shaft 2 . Note that the gap between the tractor cover 13 and the tractor plate 12 is 0.7 mm, so the distance between the top end of the projection 5 and the inner surface of the tractor cover 13 is 1 mm (=0.7 mm+0.3 mm) when the washer 6 is in the reference position.
When the form is transported by the pin feed tractor, the projection 5 is held in a position where the top end thereof is back about 0.2 mm from the inner surface of the tractor plate 12 so that the transportation of the form is not hindered by the projection 5 . With the use of the stepping motor 1 that rotates 7.5° per one step, the number of steps per one rotation is calculated by the following equation:
360°/7.5°=48 steps/rotation.
Because the male screw portion 2 ′ formed on the rotor shaft 2 has a pitch of 0.5 mm, the moving distance of the projection 5 per one step of the stepping motor 1 is calculated by the following equation:
0.5 mm/48 steps=0.0102 mm/step.
Accordingly, the movement of the projection 5 can be controlled with a resolution of about 1/100 mm.
FIG. 5 shows, in block form, the stepping motor control circuit 20 , the stepping motor drive circuit 30 connected to the control circuit 20 , and the stepping motor 1 connected to the drive circuit 30 . The control circuit 20 includes a microcomputer 21 and a non-volatile memory 22 connected to the microcomputer 21 through a bus. The microcomputer 21 has an input port connected to the switch 16 for receiving ON/OFF signal of the switch 16 , and an output port for outputting a rotational direction set (RDS) signal, a drive signal, and phase change (PC) pulses to the drive circuit 30 . The number of phase change pulses (Ss.s, Ss.m, Ss.l, Sf.s, Sf.m. Sf.l) output to the driver circuit 30 and results (Sx) of prescribed arithmetic operations to be described later are written in and read from the memory 22 when the case demands.
The drive circuit 30 includes a slow-up/slow-down controller 31 , an energization signal generator 32 , and a driver 33 . The slow-up/slow-down controller 31 is supplied with the drive signal for energizing the stepping motor 1 , the phase change pulses for changing phases 1 to 4 , and the rotational direction set signal for designating the rotational direction of the motor 1 . The slow-up/slow-down controller 31 and the energization signal generator 32 are connected by a bus, and the energization signal generator 32 is connected to the driver 33 . The driver 33 includes four parallel circuits, each including a diode (D 1 to D 4 ) and a transistor (TR 1 to TR 4 ) connected in series between a power source (+24V) and ground. The outputs of the energization signal generator 32 are connected to the respective ones of the bases of transistors TR 1 to TR 4 to selectively render the transistors ON. With the above-described arrangement, the drive circuit 30 drives the stepping motor 1 in two-phase energization.
The stepping motor 1 includes coils 1 to 4 supplied with a DC 24 V. The coils 1 to 4 are connected to the driver 33 and selectively and sequentially energized by the drive circuit 30 . The rotor of the stepping motor 1 is incrementally moved through a series of discrete movements or steps as a result of a corresponding number of discrete changes in the energization of the windings of the stator of the stepping motor 1 .
Next, the concept of the form thickness measurement according to the embodiment of the present invention will be described with reference to FIGS. 3 and 4. Firstly, a, reference distance will be measured with the form unloaded. The reference distance indicates a distance from the top end of the projection 5 held in a position where the washer 6 is in contact with the contact points 15 A and 15 E (hereinafter the position on the contact points 15 A an d 15 B will be referred to as “reference position”) to the inner surface of the tractor cover 13 . Then, an actual distance will be measured with the form loaded. The actual distance indicates a distance from the top end of the projection 5 when the washer 6 is in the reference position to the form supported on the tractor cover 13 .
Referring to FIG. 3, measurement of the reference distance will be described.
Firstly, the contact of the switch 16 is checked. Before checking the switch contact, the washer 6 is positioned in a start position where the washer 6 is separated from the contact points 15 A and 15 B. From this condition, the pressing block 4 is moved toward the substrate 7 by reversely rotating the stepping motor 1 at a pulse rate of 100 PPS. When the washer 6 impinges against the contact points 15 A and 15 B, i.e., when the switch 16 is ON, the stepping motor 1 stops its rotation. As shown in FIG. 2, when a load exceeding a pull-out torque is imparted upon the stepping motor 1 , the rotor shaft 2 is pulled out and stops its rotation.
When it is confirmed that the switch 16 is in order, the projection 5 is moved toward the tractor cover 13 to impart weak pressing force upon the tractor cover 13 . To this end, the stepping motor 1 is forwardly rotated at a high pulse rate (460 PPS). High pulse rate rotations of the stepping motor 1 impart weak pressing force upon the tractor cover 13 . When the projection 5 impinges against the tractor cover 13 , the stepping motor 1 is pulled out and stops its rotation. In this condition, the washer 6 is positioned Ls.s away from the reference position.
Next, measurement of distance Ls.s is performed. To this end, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS) until the washer 6 moves back to the reference position. The number of phase change pulses (Ss.s) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Ss.s is representative of the distance Ls.s. In order that the stepping motor 1 may not be pulled out before the washer 6 arrives at the reference position, a low pulse rate (100 PPS) is selected to generate strong torque.
Next, the projection 5 is moved toward the tractor cover 13 to impart middle pressing force upon the tractor cover 13 . To this end, the stepping motor 1 is forwardly rotated at a middle pulse rate (370 PPS). Middle pulse rate rotations of the stepping motor 1 impart middle pressing force upon the tractor cover 13 when the projection 5 impinges against the tractor cover 13 . When the projection 5 impinges against the tractor cover 13 , the stepping motor 1 is pulled out and stops its rotation. In this condition, the washer 6 is positioned Ls.m away from the reference position.
Next, measurement of the distance Ls.m is performed. To this end, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS) until the washer 6 moves back to the reference position. The number of phase change pulses (Ss.m) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Ss.m is representative of the distance Ls.m. In order that the stepping motor 1 may not be pulled out before the washer arrives at the reference position, a low pulse rate (100 PPS) is again selected to generate strong torque.
Next, the projection 5 is moved toward the tractor cover 13 to impart strong pressing force upon the tractor cover 13 . To this end, the stepping motor 1 is forwardly rotated at a low pulse rate (250 PPS). Low pulse rate rotations of the stepping motor 1 impart high pressing force upon the tractor cover 13 when the projection 5 impinges against the tractor cover 13 when the projection 5 impinges 77 upon the tractor cover 13 , the stepping motor 1 is pulled out and stops its rotation. In this condition, the washer 6 is positioned Ls.l away from the reference position.
Next, measurement of distance Ls.l is performed. To this end, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS) until the washer 6 moves back to the reference position. The number of phase change pulses (Ss.l) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Ss.l is representative of the distance Ls.l. In order that the stepping motor 1 may not be pulled out before the washer 6 arrives at the reference position, a low pulse rate (100 PPS) is selected to generate strong torque.
After measurement of three values Ss.s, Ss.m and Ss.l, the stepping motor 1 is forwardly rotated at a pulse rate of 100 PPS to retract the pressing block 4 to the start position.
In this manner, the reference distance is measured thrice while imparting three differing pressing forces upon the tractor cover 13 . Measurement of the reference distance for three times is necessary to investigate resilient deformation of the tractor cover 13 which changes with the strength of the pressing force. The reference distance thus measured will be used to improve accuracy of the form thickness measurement.
Next, a form to be measured is loaded in the pin feed tractor and a distance from the reference position to the form (hereinafter referred to as “actual distance”) will be measured.
Referring to FIG. 4, measurement of the actual distance will be described.
Firstly, the contact of the switch 16 is checked in the same manner as is done in the measurement of the reference distance.
Assuming that the form includes a single sheet of paper, weak pressing force is imparted upon the form. To this end, the stepping motor 1 is forwardly rotated at a high pulse rate (460 PPS). Because pressing a single sheet of paper with strong force lowers the measurement accuracy, weak pressing force is imparted upon the paper. In this condition, the washer 6 is positioned Lf.s away from the reference position.
To measure Lf.s, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS). The number of phase change pulses (Sf.s) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Sf.s is representative of the distance Lf.s. In order that the stepping motor 1 may not be pulled out before arriving at the reference position, the pulse rate is set to low (100 PPS) to generate strong torque.
Assuming that the form includes five to six sheets of paper, middle pressing force is imparted upon the form. To this end, the stepping motor 1 is forwardly rotated at a middle pulse rate (370 PPS). The middle pressing force is selected to a value such that no mark of depression by the projection 5 appears on pressure-sensitive sheets, and that a form consisting of plural sheets of paper is not detected thicker than an actual thickness, which may otherwise be detected thicker due to bulkiness of the form. Upon impingement of the projection 5 upon the form, the stepping motor 1 is pulled out and stops its rotation. In this condition, the washer 6 is positioned Lf.m away from the reference position.
To measure the distance Lf.m, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS) from the position where the stepping motor 1 is pulled out. The number of phase change pulses (Sf.m) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Sf.m is representative of the distance Lf.m. In order that the stepping motor 1 may not be pulled out before arriving at the reference position, the pulse rate is set to low (100 PPS) to generate strong torque.
Assuming that the form includes eight sheets of paper, strong pressing force is imparted upon the form. To this end, the stepping motor 1 is forwardly rotated at a low pulse rate (250 PPS). The actual strength of the strong pressing force is selected to a value such that no mark of depression by the projection 5 appears on the sheets, and that a form consisting of plural sheets of paper is not detected thicker than an actual thickness, which may otherwise be detected thicker due to bulkiness of the form. Upon impingement of the projection 5 upon the form, the stepping motor 1 is pulled out and stops its rotation. In this condition, the washer 6 is positioned Lf.l distance away from the reference position.
To measure the distance Lf.l, the stepping motor 1 is reversely rotated at a low pulse rate (100 PPS) from the position where the stepping motor 1 is pulled out. The number of phase change pulses (Sf.l) generated during the reversal movement of the stepping motor 1 is counted and stored in the non-volatile memory 22 . The number of phase change pulses Sf.l is representative of the distance Lf.s. In order that the stepping motor 1 may not be pulled out before arriving at the reference position, the pulse rate is set to low (100 PPS) to generate strong torque.
Upon measurement of the distance Lf.l, the stepping motor 1 is forwardly rotated at a pulse rate of 100 PPS to retract the pressing block 4 to the start position.
Based on the measurement results, the following computations are performed:
Sx.s=Ss.s−Sf.s (1)
Sx.m=Ss.m−Sf.m (2)
Sx.l=Ss.l−Sf.l (3)
Further, two reference value Ref. 1 and Ref. 2 are set for comparison with the computation results wherein first reference value Ref. 1 is smaller than second reference value Ref. 2 .
When Sx.s is smaller than the first reference value Ref. 1 , it is determined that the form consists of a single sheet of paper. When Sx.m is greater than the first reference value Ref. 1 but is less than the second reference value Ref. 1 , then it is determined that the form consists of two to six sheets of paper. When Sx.l is greater than the second reference value Ref. 2 , then it is determined that the form consists of more than seven sheets of paper.
It should be noted that the values Ss.s, Sf.s and Ss.m need not be measured each time the form thickness is measured. These values are measured in advance and stored in the memory 22 . Further, it is not necessary to measure Sf.m and Sf.l if it is determined that the form consists of a single sheet of paper. Also, it is not necessary to measure Sf.l if it is determined that the form includes less than eight sheets of paper.
The form thickness can be obtained by converting the number of phase change pulses Sx to a unit of length using a relation that one phase or one step corresponds to 0.01042 mm as described before.
Determination of the first and second reference values REF. 1 and REF. 2 will be described while referring to FIG. 8 .
FIG. 8 shows various kinds of forms, their measured thickness, and their measured step number. The form thickness is measured using a high precision measuring instrument. From the data shown in FIG. 8, it can be appreciated that step number 25 can be used as a boundary for discriminating forms of a single sheet of paper from forms of plural sheets of paper. Also, step number 42 can be used as a boundary for discriminating forms of five or six sheets of paper from forms of eight sheets of paper. As such, 25 and 42 are used as the first and second reference values REF. 1 and REF. 2 , respectively.
Next, operation of the form thickness measuring device 100 will be described with reference to FIGS. 6-7, 9 - 10 and 11 ( a ) to 11 ( d ).
The flowchart of FIG. 9 is directed to the measurement of the reference distance described with reference to FIG. 3 . First, check of switch contact (CSC) is executed (S 1 ). The sub-routine of CSC is depicted in the flowchart of FIG. 11 ( a ). As shown therein, the pulse rate is set to 100 PPS (S 41 ) and the drive direction set signal is rendered low to instruct the stepping motor drive circuit 30 to rotate the stepping motor 1 reversely (S 42 ). When the drive signal is applied to the stepping motor drive circuit 30 , the stepping motor 1 starts rotating reversely (S 43 ). The stepping motor 1 keeps on rotating while changing phases (S 44 ), and the pressing block 4 moves toward the substrate 7 . When it is determined that the switch 16 is rendered ON (S 45 : YES) by the contact of the washer 6 with the contact points 15 A and 15 B, the stepping motor 1 is pulled out and stops its rotation (S 46 ). Through these processes, it can be confirmed that the switch 16 is in order.
When the sub-routine of FIG. 11 ( a ) is ended, the routine returns to S 2 of the main routine of FIG. 9 where the pulse rate is set to 460 PPS (S 2 ). Then, pressing process is executed (S 3 ). The sub-routine of the pressing process is depicted in the flowchart of FIG. 11 ( b ). As shown therein, the drive direction set signal is rendered high to instruct the stepping motor drive circuit 30 to rotate the stepping motor 1 forwardly (S 51 ). Then, N is set to 100 (S 52 ) where N indicates a predetermined number of phase change pulses or a predetermined number of steps. N is set to a number corresponding to a distance slightly longer than the distance to be measured. The gap sensor 10 is designed so that the projection 5 is brought into contact with the inner surface of the tractor cover 13 when it is moved from the position where the washer 6 is in the reference position by a distance corresponding to 97 steps. When the drive signal is applied to the stepping motor drive circuit 30 , the stepping motor 1 starts rotating forwardly (S 53 ). The stepping motor 1 keeps on rotating while changing phases (S 54 ). Each time the phase changes, N set to 100 is decremented by one (S 55 ). Immediately before N becomes equal to zero (S 56 : YES), the projection 5 impinges against the tractor cover 13 , so that the stepping motor 1 is pulled out and stops its rotation (S 57 ). Because the stepping motor 1 is rotating at a high pulse rate (460 PPS), it imparts weak pressing force upon the tractor cover 13 .
When the sub-routine of FIG. 11 ( b ) is ended, the routine returns to S 4 of the main routine of FIG. 9 where measurement process is executed. The sub-routine of the measurement process is depicted in the flowchart of FIG. 11 ( c ). As shown therein, the pulse rate is set to 100 PPS (S 61 ) and the drive direction set signal is rendered low to instruct the stepping motor drive circuit 30 to rotate the stepping motor 1 reversely (S 62 ). When the drive signal is applied to the stepping motor drive circuit 30 , the stepping motor 1 starts rotating reversely (S 63 ). At this time, S is set to zero (S 64 ). The stepping motor 1 keeps on rotating while changing phases (S 65 ). Each time the phase changes, S is incremented by one (S 66 ). In accordance with the reverse rotations of the stepping motor 1 , the pressing block 4 moves toward the substrate 7 . When it is determined that the switch 16 is rendered ON (S 67 : YES) by the contact of the washer 6 with the contact points 15 A and 15 B, the stepping motor 1 is pulled out and stops its rotation (S 68 ).
When the sub-routine of FIG. 11 ( c ) is ended, the routine returns to S 5 of the main routine of FIG. 9 where the number of phases or steps S counted in the preceding measurement process is stored as Ss.s in the non-volatile memory 22 . Thereafter, the pulse rate is set to 370 PPS (S 6 ) and the pressing process as described with reference to the sub-routine of FIG. 11 ( b ) is executed (S 7 ). In this case, because the stepping motor 1 is rotating at a middle pulse rate (370 PPS), it imparts middle pressing force upon the tractor cover 13 . After the pressing process (S 7 ), the measurement process as described with reference to the sub-routine of FIG. 11 ( c ) is executed (S 8 ). Then, the value of S is stored as Ss.m (S 9 ).
Next, the pulse rate is set to 250 PPS (S 10 ), and the pressing process is executed (S 11 ). In this case, because the stepping motor 1 is rotating at a low pulse rate (250 PPS), it imparts strong pressing force upon the tractor cover 13 . After the pressing process (S 11 ), the measurement process is similarly executed (S 12 ). Then, the value of S is stored as Ss.l (S 13 ).
Following S 13 , the pressing block 4 is retracted to the start position (S 14 ). The process of retraction to start position (RTSP) is depicted in the sub-routine of FIG. 11 ( d ). As shown therein, the pulse rate is set to 100 PPS (S 71 ) and the drive direction set signal is rendered high to instruct the stepping motor drive circuit 30 to rotate the stepping motor 1 forwardly (S 72 ). Then, N is set to 10 (S 73 ) where N indicates a predetermined number of phase change pulses. 10 set to N corresponds to a distance from the reference position to the start position. When the drive signal is applied to the stepping motor drive circuit 30 , the stepping motor 1 starts rotating forwardly (S 74 ). The stepping motor 1 keeps on rotating while changing phases (S 75 ). Each time the phase changes, N set to 10 is decremented by one (S 76 ). When N becomes equal to zero (S 77 : YES), application of the drive signal to the drive circuit 30 is stopped, thereby stopping rotations of the stepping motor 1 (S 78 ). Through the process of RTSP, the pressing block 4 is retracted to the start position and the main routine of FIG. 9 is ended.
Next, measurement of the actual distance will be described with reference to the flowchart of FIG. 10 .
First, check of switch contact (CSC) is executed (S 21 ) in the same manner as in S 1 of the FIG. 9 flowchart. The sub-routine of CSC is depicted in the flowchart of FIG. 11 ( a ). When it is confirmed that the switch 16 is in order, the pulse rate is set to 460 PPS (S 22 ). Then, pressing process is executed (S 23 ) in the same manner as in S 3 of the FIG. 9 flowchart. The sub-routine of the pressing process is depicted in the flowchart of FIG. 11 ( b ). In this occasion, weak pressing force is imparted upon the foam.
Following the pressing process (S 23 ), measurement process is executed (S 24 ) in the same manner as in S 4 of the FIG. 9 flowchart. The sub-routine of the measurement process is depicted in the flowchart of FIG. 11 ( c ).
When the measurement process (S 24 ) is ended, the value of S is stored as Sf.s in the non-volatile memory 22 , Ss.s stored therein is read, computation of Sx=Ss.−Sf.s is performed, and the resultant data Sx is stored in the memory 22 (S 25 ).
In S 26 , determination is made as to whether or not Sx is equal to or greater than the first reference value REF. 1 which is set to 25 in this embodiment. When Sx is less than 25 (S 26 : NO), then it is determined that the form consists of a single sheet of paper. Because in this case, no further determination is necessary, the pressing block 4 is retracted to the start position (S 27 ) and the program of FIG. 10 is ended.
When Sx is equal to or greater than 25 (S 26 : YES), it is determined that the form does not consist of only one sheet of paper but consists of five sheets of paper or more.
Then, the pulse rate is set to 370 PPS (S 28 ) and the pressing process as described with reference to the sub-routine of FIG. 11 ( b ) is executed (S 29 ). In this case, because the stepping motor 1 is rotating at a middle pulse rate (370 PPS), it imparts middle pressing force upon the foam. After the pressing process (S 29 ), the measurement process as described with reference to the sub-routine of FIG. 11 ( c ) is executed (S 30 ). Then, the value of S is stored as Sf.m in the non-volatile memory 22 , Ss.m stored therein is read, computation of Sx=Ss.m−Sf.m is performed, and the resultant data Sx is overwritten in the memory 22 (S 31 ).
In S 32 , determination is made as to whether or not Sx is equal to or greater than the second reference value REF. 2 which is set to 42 in this embodiment. When Sx is less than 42 (S 32 : NO), then it is determined that the form consists of five or six sheets of paper. Because in this case, no further determination is necessary, the pressing block 4 is retracted to the start position (S 33 ) and the program of FIG. 10 is ended.
When Sx is equal to or greater than 42 (S 32 : YES), it is determined that the form includes eight sheets of paper. Then, the pulse rate is set to 250 PPS (S 34 ) and the pressing process as described with reference to the sub-routine of FIG. 11 ( b ) is executed (S 35 ). In this case, because the stepping motor 1 is rotating at a low pulse rate (250 PPS), it imparts strong pressing force upon the tractor cover 13 . After the pressing process (S 35 ), the measurement process as described with reference to the sub-routine of FIG. 11 ( c ) is executed (S 36 ). Then, the value of S is stored as Sf.l in the non-volatile memory 22 , Ss.l stored therein is read, computation of Sx=Ss.l−Sf.l is performed, and the resultant data Sx is overwritten in the memory 22 (S 37 ). Then, the pressing block 4 is retracted to the start position (S 33 ) and the program of FIG. 10 is ended.
The counted step number Sx stored in S 25 , S 31 or S 37 is read from the memory 22 and is converted to a unit of thickness as described before. Through the conversion, the thickness of the form loaded in the pin feed tractor is obtained.
While an exemplary embodiment of this invention has been described in detail, those skilled in the art will recognize that there are many possible modifications and variations which may be made in this exemplary embodiment while yet retaining many of the novel features and advantages of the invention. Accordingly, all such modifications and variations are intended to be included within the scope of the appended claims. | A thickness of a form document loaded in a pin feed tractor is measured to appropriately adjust a gap between a platen and a print head. A projection formed on a pressing block is linearly moved toward and away from the form document supported on a tractor cover. The pressing block is moved by a stepping motor, and an amount of rotations of the stepping motor is detected to measure the movement of the projection. A first amount of rotations is detected under a condition where the form document is not loaded and subsequently a second amount of rotations is detected under a condition where the form document is loaded. The thickness of the form document is computed based on a difference between the first amount of rotations and the second amount of rotations to eliminate influence of resilient deformation of the tractor cover. | 1 |
BACKGROUND
The present invention relates to automatic barrier movement operators.
Barrier movement systems are known in the art and generally comprise a motor for moving the barrier in response to a controller which determines necessary actions by responding to barrier travel limits, safety apparatus and user command input signals. With such known systems the travel limit determining apparatus is maintained at the controller and represents the controller's view of the barrier. Should the barrier, be disconnected from the controller and moved, the barrier position may become unknown leading to lack of ability to automatically control the barrier.
Similarly, known systems may respond to a number of safety input devices, such as edge contact sensors or optical obstruction detectors, which is limited by the number of input ports provided for such. This is particularly so in commercial door operators or gate operators where the eventual equipping of the system depends on an unpredictable environment and the needs of the users and installers of such devices. Such a problem is quite complex for gate operators where the number of combinations of optical detectors and edge detectors is large and depends on factors unknown at the time the system is manufactured.
Known systems include the ability to optionally respond to wireless communications. Such systems typically require separate decoders for each wireless transmitter or type of transmitter resulting in undue complexity and cost. Also known systems typically start and stop barrier movement with a linear increase and decrease of power applied to a driving motor. Such systems do not pay continuing attention to barrier position and may result in efficient barrier movement or a barrier which moves too slowly or even stops before a destination limit of travel.
SUMMARY
The above disadvantages are overcome in accordance with the barrier movement operator described and claimed herein.
In accordance with one embodiment apparatus for generating position signals is disposed remotely from a controller of the apparatus and periodically reports position signals to the controller. Advantageously, the position sensor may comprise circuitry for producing an analog representation of position and an analog to digital convertor for periodically reporting digital position signals to the controller.
An embodiment also includes the ability to operate with an expanded number of safety devices such as edge contact detectors and optical obstruction detectors. Advantageously, the two types of safety devices produce non-interfering normal and safety signals so that different types of safety devices can be connected to the same input terminal. Upon receipt of a safety alerting signal the controller determines which type of device generated the signal and then performs a safety action associated with the signaling type of device.
The described and claimed barrier movement system also may respond to wireless user commands. Advantageously, the controller includes a single decoder which learns wireless input commands directed toward different operator functions such as movement of one barrier, movement of another barrier and movement of both barriers. The wireless commands are learned in a manner which can be used to duplicate the appropriate action when subsequent receptions of the same wireless command occur during an operate mode of the device. The fact that a received wireless command matches a previously learned command is reported to the controller on a separate communication path associated with the functions to be performed.
An improved method of setting limits of barrier travel is also described and claimed herein. Upon initiation of a limit learn function a barrier is moved to an end limit and a command signal is sent to the controller which responds by storing the end limit. The barrier is then moved to the other end limit, the position of which is stored by the controller in response to another command signal. The command signals may be produced by user inter action with a command button of the controller or by wireless transmissions.
Power is reduced to the barrier moving motor when a predetermined position of travel is reached with regard to an end limit. Such reduction of power is achieved by reducing the applied power in a non-linear function based on the actual position of the barrier as it slows. The non-linear reduction of power may be achieved, for example, by reducing power by a predetermined amount identified by barrier position. Non-Linear reduction may also be achieved by calculating the amount of power needed to reduce applied power to a predetermined minimum power. When power is being reduced it is possible that the barrier will move too slowly or stop altogether. Advantageously, the speed of barrier movement can be determined from recent position signals and, when too slow, power can be increased to provide a minimum rate of barrier travel.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is a combined schematic of an automatic gate operator;
FIG. 2 is a cross-sectional view of a telescoping used to move the gates of FIG. 1 ;
FIGS. 3 and 4 show portions of the telescoping arm in retracted position and extended position respectively;
FIG. 5 is a schematic diagram of a position sensor signal generator;
FIG. 6 is a combined block diagram and structural diagram of the safety equipment used in a gate operator;
FIG. 7 is a block diagram of a controller for the gate operator;
FIG. 8 is a schematic diagram of electrical connections to a set of input terminals; and
FIGS. 9 and 10 are representations of power applied to a motor to move the gate of the gate operator system.
DESCRIPTION
FIG. 1 represents a barrier movement operator embodied as a gate opening and closing system. Although the embodiments and examples are written in terms of an automatic gate operator, it is to be understood that the principles discussed herein are equally applicable to other barrier operators such as garage door operators, solid door movers and window or shutter controllers. The gate operator system includes a pair of gates 11 and 13 each of which is mounted to swing from a respective post 10 mounted on either side of a passageway 51 ( FIG. 6 ). A telescoping arm assembly 150 is connected between a post 10 and gate 11 and another telescoping arm assembly 150 is connected between the other post 10 and gate 13 . The gates are individually moved by extending and retracting a portion 20 of the arm 150 . The extension and retraction are controlled by signals from a control unit 15 which is in overall control of the barrier movement system. Control unit 15 responds to user commands to open and close the gates and also responds to feedback information from the telescoping arms 150 and information from photo eyes 17 and 18 and edge contact sensors 24 and 25 .
A more detailed representation of a telescoping arm is presented in FIG. 2 . Telescoping arm 150 includes an electric motor 27 which rotates in response to electrical power provided from controller 15 via conduction path 29 . In the disclosed embodiment motor 27 is a DC motor responding to pulse width modulated power however, it is to be understood that other types of electrical motors may be used when their rotation speed and/or output power can be controlled. The power output of motor 27 is connected by a rotation coupling 36 to a drive end 32 of a screw shaft extension. Coupling 36 provides gear reduction from motor 27 and permits a user to decouple the motor from drive 32 . The make-up of coupling 36 is not described in detail herein. Drive end 32 is coupled by an extension 121 to rotate an elongated screw shaft 34 .
Telescoping arm 150 comprises an outer tube 40 having therein an inner extension tube 20 . A nut 102 having threads to mate with the threads of screw shaft 34 is disposed at an inner end of inner tube 20 . Accordingly, when drive 32 is rotated, screw shaft 34 rotates and inner tube 20 is extended or retracted from and into outer tube 40 depending on the direction of rotation. The pitch of screw threads on shaft 34 is such that on the order of 8 or 9 revolutions of shaft 34 will fully extend or fully retract the inner tube 20 . It should also be mentioned that when the motor 27 is decoupled from drive end 32 , the inner tube 20 can be extended and retracted by pulling and pushing thereon. Such manual extension and retraction causes a rotation of screw shaft 34 in the same amount as occurs from motor 27 , when coupled.
Extension shaft 121 is coupled by means of a driving belt 120 to a 10 turn potentiometer 38 . The relative diameters of shaft 121 and the control shaft of potentiometer 38 are such that a complete extension of inner tube 20 results in less than 10 rotations of the potentiometer shaft. Thus, the range of potentiometer is not exceeded during a full extension or retraction of the inner tube 20 . The wiper 42 of potentiometer is connected as an input to an analog to digital converter 44 which is disposed within telescoping arm 150 along with the potentiometer 38 . As shown in FIG. 5 the fixed ends of the potentiometer resistance are respectively connected to a reference voltage and to ground so that as the shaft 34 rotates, either by the action of motor 27 or manual action, a variable voltage is applied to the analog to digital convertor 44 . In FIG. 5 analog to digital converter is represented as a microprocessor 44 which both produces digital representations of the analog position voltage and serially transmits those digital representations from the telescoping arm 150 to the controller 15 . Microprocessor 44 is programmed to periodically transmit the digital position representing signals approximately every 50 m sec although other periods of transmission could be used.
FIG. 6 is a plan view of the barrier movement apparatus showing particularly the safety apparatus which may be associated with the gate. Posts 10 are disposed at either side of passageway 51 . The gates 11 and 13 are attached to posts 10 to swing in an orientation which opens and closes access along the passageway. A plurality of photo eye pairs are disposed to form a frame around the area over which the gates swing. The pair of photo eyes 17 – 18 surveys a line across the passageway next to posts 10 while a pair of photo eyes 47 – 48 surveys the passageway just beyond the ends of the open gates. Each side of the passageway may also be protected by a pair of photo eyes. Photo eyes 53 – 54 survey one side of the passageway just outside the travel of gate 11 and photo eyes 56 – 57 survey a similar site on the gate 13 side. The photo eyes are electrically connected in pairs for communications with controller 15 . An optical beam is normally transmitted from one photo eye e.g., 47 to another of the pair e.g., 48 . When the optical beam is properly received the photo eye pair returns a predetermined voltage with periodic drops to zero volts to the controller 15 . In an embodiment the drops to zero volts occur approximately every 7 m sec. When an obstruction breaks the optical beam the voltage remains at the predetermined voltage level without drops to zero volts and remains so until the obstruction is removed. Controller 15 is programmed to respond to a signal identifying an optically detected obstruction by stopping all movement of the gates until the obstruction is removed and proper signals are again received.
The edge contact obstruction sensors e.g., 24 and 25 are also connected to provide safety signals to controller 15 . Edge sensors 24 and 25 are normally open contact switches the contacts of which have a predetermined edge sensor voltage applied between them. Normally the edge sensor voltage is detected by controller 15 indicating that no obstruction has been touched. Alternatively, when an obstruction is touched the normally open contacts are shorted and the voltage detected by the controller 15 drops to substantially zero and remains there until the edge sensor e.g., 24 is no longer touching an obstruction. Some edge sensors also include a known resistance connected between the sensor contacts at one end of the edge sensor. This permits the controller 15 to check for a constant current for assurances of a working sensor, but a signal of zero volts is still the safety signal. Thus, an edge safety signal comprises a drop of voltage sensed by controller 15 to substantially zero volts. Controller 15 is programmed to respond to an edge sensor safety signal by reversing the travel of all moving gates for a fixed distance.
The safety signals from edge sensors e.g., 24 and from photo eye pairs e.g., 47 – 48 are all applied to a set of input terminals 59 which are shown in greater detail in FIG. 8 . Each input terminal 61 – 64 can be connected to one or more safety devices of either optical (photo eye) or edge contact type. When both optical and contact type sensors are connected to a terminal, that terminal will exhibit a predetermined voltage with near zero drops at an approximately a 7 m sec period when neither device has an obstruction. That is, the near zero drops by the optical sensor will pull the contact sensor voltage to zero for the time of the drops. Should the contact sensor strike an obstruction the voltage on the line will be pulled to a constant near zero. If instead the optical sensor is blocked by an obstruction the terminal will remain high which will be detected because the near zero drops on the input were present, but have gone away. Controller 15 periodically scans the input terminals 61 – 64 to determine that no safety signals are present. When a safety signal is detected, controller 15 identifies whether it is an optical safety device or a contact safety device which is creating the signal and takes appropriate action. That is, when the detected safety signal is from an edge contact sensor the direction of movement is reversed and when an optical safety signal is detected, gate movement is not started or stopped if motion is occurring. The input terminals 61 – 64 can be shared because the optical safety signal is a constant predetermined voltage while the edge contact safety signal is a constant near zero volt signal.
During the set up of the gate operator the controller 15 is taught the end limits of travel of the gates. First, the user presses a limit learn button 66 ( FIG. 7 ) to which processor 68 of controller 15 responds by entering the limit learn mode. The user then uncouples the motor 27 from the extension screw 34 , if not already done, and manually moves a first gate to either the open or the closed position and signals such by pressing manual gate operator control button 70 . Then the user manually moves the gate to the other limit position and again presses the control button 70 . When, as shown in FIGS. 1 and 6 , two gates are present the user repeats the process with the second gate. The controller 15 records in memory the digital representation of position from analog to digital controllers 44 at each open and closed limit for each gate. The gate can be controlled to move between the stored position limit values. It may be desirable for the controller to know which stored position limit corresponds to an open gate and a closed gate. In embodiments where such is desired the controller is programmed to expect the position limits for a predetermined state such as closed first. On the preceding limit setting process, limits were identified when a user pressed a control button 70 . When the barrier movement system is equipped with wireless command capability (discussed below), wireless commands can also be used to identify limits in the same manner as button 70 .
The barrier movement system of the present description may also include a wireless security code transmitter 72 which can wirelessly initiate movement of one or more of gates 11 and 13 . Transmitter 72 transmits gate commands by RF signals, however, other types of wireless signaling such as optical or acoustic could be used. Controller 15 includes an RF receiver 74 which receives transmission from transmitter 72 via an antenna 76 . Representations of received signals are sent to a decoder 78 which validates selected received signals and notifies processor 68 via one of a plurality of conductors of which conductor 81 , 82 and 83 . Validation of a received RF transmission is done on the basis of transmitted security codes and before validation can occur, the decoder 78 is taught values which are later compared to received security codes to complete validation or not.
Decoder 78 includes a microprocessor and memory which are programmed to operate in a learn mode and in an operate mode. Although different numbers of such buttons could be provided, decoder 78 is connected to three learn buttons 85 , 86 and 87 . In the present embodiment button 85 represents a learn mode for movement of gate 13 , button 86 represents a learn mode for gate 11 and button 87 represents a learn mode for both gates.
Transmitter 72 includes three transmit buttons 90 , 91 and 92 , each of which is associated by transmitter 74 with a unique security code. When a transmit button e.g., 90 is pressed an RF transmission is sent which includes the security code unique to the pressed button. When a user wants to train the controller 15 to validate and respond to a wireless security code, such a security code must be stored by the decoder 78 . When the user wants the security code to control gate 13 , 11 , or both, a button 85 , 86 or 87 respectively is pressed to enter the learn mode for the correct gate or combination. The user then presses the button on transmitter 72 which is to perform the desired control. Upon pressing the appropriate transmitter button e.g., 90 the decoder 78 , via receiver 74 , receives a representation of the unique code associated with button 90 and stores it in a manner which identifies the gate or gates which are to respond to the newly stored code. After the received security code is stored in decoder 78 , the decoder switches from the learn mode to the operate mode. Subsequent receipts of the code from transmitter 72 button 90 will cause decoder to send a command to processor 68 via a selected one of conductors 81 , 82 or 83 . The particular conductor 81 , 82 or 83 selected, defines whether gate 11 , 13 or both are to operate. Finally, when processor 68 receives a command on one of conductors 81 , 82 or 83 the gate or gates associated with that conductor are controlled.
Processor 68 of controller 15 responds to input signals from decoder 78 , command button 70 and the safety input by starting, moving and stopping one or both gates. Such control is exercised by sending pulse width modulated DC to one or both of the motors 27 of telescoping arms 150 . A gate is started from a first limit (limit 1 , FIG. 9 ) by applying approximately 25% of full power which is ramped upward to achieve 100% power at a predetermined point of gate travel X 1 . The power level remains 100% until the gate achieves a second point X 2 at which the power is diminished until the 25% level is achieved at the destination end point. In the embodiment represented by FIG. 9 the power is not linearly ramped down in the reverse of the up ramp of start up power. Instead the power is non-linearly reduced to achieve a safe and efficient slowing and stopping the gate. Such non-linearly power reduction is achieved by reducing the power based on gate position as reported by the position sensing potentiometer 38 and analog to digital converter 44 .
In a first embodiment after gate position X 2 is achieved the power may be reduced by a predetermined amount for each gate position reported from the telescoping arm 150 . Such reductions are pre-established to achieve the non-linear reduction in power represented in FIG. 9 . Alternatively, power may be reduced by calculating, for each reported gate position, the amount of power estimated to achieve 25% by the destination limit 2 . In either case, the non-linear reduction is achieved by reducing power based on door position.
For reasons such as wear and tear on the gates as they age it is possible that the forces required to move the gate may be unpredictable. When the gate is speeding up or traveling at full power such required force will be overcome by the relatively high power levels. When power is being reduced it is possible that the unpredictable forces will cause the gate to move more slowly than desired or even stop. FIG. 10 represents an embodiment employed to overcome the slow or stopped gate situation. As before the non-linear power reduction begins when a position X 2 is indicated for the gate. As in FIG. 9 the power reduction is reduced based on gate position, however, the times and gate positions of recent reportings are also considered to estimate the speed at which the gate is moving. Such speed maybe, for example, determined from the last 5 position reports. When the speed falls below a predetermined amount given the current gate position, the power level is increased to achieve at least a predetermined rate. In one specific embodiment if the gate position is reported as the same (no movement) for the predetermined number of reports e.g., 5, the power is increased beginning at point 98 where no movement was detected. Such increase continues until the speed calculation indicates an adequate speed for safety and efficiency. | A barrier movement operator is having a position sensor in a telescoping barrier control arm is described. A controller, remote from the arm, senses the barrier position to identify limits of barrier travel and to control rate of travel of the barrier between limits. The operator includes both optical and edge sensor obstruction detectors and is responsive to wireless communication for receiving user initiated command signals. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cordless electric flatiron which utilizes an internal heat storage element and a temperature regulator.
2. The Prior Art
Electric flatirons which include internal heat storage elements that are electrically heated when the flatirons are in use are quite well known. However, such known flatirons are only operable if they are continuously connected to an electrical outlet, and the attached electrical cables make them at times very cumbersome to use. In addition, the electrical cables themselves can be easily damaged and they also tend to make these flatirons quite bulky to store away.
On the other hand, a cordless electric flatiron has been marketed which avoids the noted problems. However, this known cordless flatiron can only be used in conjunction with a special, expensive stand, and this flatiron must be frequently placed on this special stand because its heat capacity is very small.
It is thus an object of the present invention to provide a cordless electric flatiron which is capable of storing a great deal of heat, such that it need be connected to a source of electrical power only relatively infrequently.
SUMMARY OF THE INVENTION
According to the present invention, the cordless electric flatiron includes an electrically heated heat storage element which is mounted in a chamber in the iron to be movable with respect to the bottom sole plate of the iron, as well as a temperature-responsive regulator element which can, based on the temperature of the sole plate, move the heat storage element (or an intermediate element positioned between the sole plate and the heat storage element) toward and away from the sole plate to control the amount of heat transferred by conduction from the heat storage element to the sole plate and thus the temperature to which the sole plate is heated. In addition, the inventive cordless electric flatiron includes a temperature selector which controls how (when) the temperature-responsive regulator element moves the heat storage element (or an intermediate element) with respect to the sole plate and thus the temperature to which the sole plate will be heated by the heat storage element.
The internal heat storage element of the inventive cordless electric flatiron can be safely heated to a relatively high temperature, as a result of which a large quantity of heat may be stored therein. This means the flatiron need be connected to a source of electrical power (which is needed to electrically heat the internal heat storage element by resistance heating) only infrequently.
The invention will now be better understood by reference to the accompanying drawings taken in conjunction with the following discussion.
DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 shows a diagrammatic side view through the operative portion of a flatiron constructed according to one embodiment of the present invention,
FIG. 2 shows a diagrammatic side through the operative portion of a flatiron constructed according to another embodiment of the present invention, as well as a diagrammatic side view through a flatiron stand that can be advantageously used therewith,
FIG. 3 shows a diagrammatic side view through the front end of a flatiron constructed according to a third embodiment.
FIG. 4 shows, on an enlarged scale, a partially broken away view of an electrical socket which can be used on the rear end of the flatiron embodiment as depicted in FIGS 3 and 5,
FIG. 5 shows a diagrammatic side view through the rear end of a flatiron shown in FIG. 3, and
FIG. 6 shows, on an enlarged scale, a view of the temperature indicator device located on the rear end of the flatiron embodiment as depicted in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of flatiron according to the present invention, generally indicated by the numeral 5, is diagrammatically shown in FIG. 1. It includes a bottom sole plate 10, a protective hood 15 and a heat storage element 20. The hood 15 is connected to the sole plate 10 around its periphery so as to form a chamber C therebetween, and the heat storage element 20 is mounted in the chamber to be movable toward and away from the flat top surface 11 of the sole plate 10. In this regard, a control rod 31 of a temperature selector 30 threadingly extends through a threaded bore 23 in the center of the heat storage element 20, the lowermost tip of the control rod 31 terminating in a cavity 22 formed in the flat bottom face 21 of the heat storage element. The upper end of the control rod 31 slidingly extends through an opening 17 in the roof 16 of the hood 15 and is fixedly connected to a rotatable knob 32. Rotation of the knob 32 will change the positioning of the heat storage element 20 along the length of the control rod 31 and thus the degree to which the lowermost tip of the control rod 31 is recessed within the cavity 22.
The bottom surface 12 of the sole plate 10 is flat and forms the useful ironing surface of the flatiron.
The heat storage element 20 is itself heated by an electrical heating rod 35 which extends within the heat storage element, the heating rod 35 being electrically connected to be supplied with electrical power from electrical plug 38 which extends outwardly from the rear side 18 of the hood 15.
An indented portion 13 is formed in the top surface 11 of the sole plate 10, and a temperature-responsive regulator in the form of a bimetallic lamella 40 is located therein. A first end of the bimetallic lamella 40 is fixedly located in the indented portion 13 while the second end, which is located below the lowermost tip of the control rod 31, is free to move upwardly as a result of bending of the bimetallic lamella. When in a cold state, e.g., when at room temperature, the bimetallic lamella 40 will tend to be in a flattened condition such that the second end thereof will be located generally within the indented portion 13, but as its temperature rises in accordance with a rise in the temperature of the sole plate 10, the bimetallic lamella 40 will bend, causing the second end to move upwardly within chamber C. Once the second end of the bimetallic lamella 40 contacts the lowermost tip of the control rod 31, further bending of the bimetallic lamella 40 will force the control rod to slide upwardly within the opening 17 and the heat storage element 20 to be concurrently moved away from the top surface 11 of the sole plate 10.
Operation of this embodiment of the inventive flatiron occurs as follows. The user first of all sets the knob 32 of the temperature selector 30 to the desired temperature for the bottom plate 10. Then the user connects the electrical plug 38 to a suitable electrical socket (see FIG. 2) until the heat generated by the heating rod 35 has supplied the desired amount of heat to the relatively massive heat storage element 20. The flow of current to the heating rod 35 will be switched off by a switch (not shown) and the electrical connection between the electrical plug 38 and the electrical socket will then be manually disconnected. During this period of time, and because the flat bottom face 21 of the heat storage element 20 will have been initially in full contact with the flat top surface 11 of the sole plate 10, the sole plate 10 will be heated up due to heat conduction. Concurrently the bimetallic lamella 40 will bend, and eventually its second end will contact the lowermost tip of the control rod 31 (the time it takes for this to happen being determined by the setting of knob 32) and thereafter will push it and the heat storage element 20 away from the sole plate 10. Once the flat bottom face 21 of the heat storage element is moved out of direct contact with the flat top surface 11 of the sole plate 10, heat transfer from the heat storage element to the bottom plate 10 will be drastically reduced, and the flatiron will be ready for use.
As the flatiron is used, the sole plate 10 will cool and concurrently the bimetallic lamella 40 will bend back towards its flattened state, such that the flat bottom face 21 of the heat storage element will again be allowed to directly contact the flat top surface 11 of the sole plate 10. Then, since the heat storage element 20 will be still capable of supplying heat to the sole plate 10, the sole plate 10 will heat up again to its desired temperature. As a result of this cyclic bending of the bimetallic lamella 40 and the cyclic movement of the heat storage element 20 into and out of contact with the top surface 11 of the sole plate 10, the temperature of the sole plate 10 will be advantageously kept within a relatively narrow temperature range. Only when the temperature of the heat stroage element 20 drops to the point that direct contact with the top surface 11 of the sole plate 10 will not enable the sole plate to be reheated to its desired temperature will the flatiron then have to be reconnected to a source of electrical current.
FIG. 2 shows another embodiment of flatiron according to the invention, generally indicated by numeral 6, together with a flatiron stand 60 with which it can be advantageously used. This flatiron 6 is constructed to provide enhanced control of the heat flow from the heat storage element 20 to the sole plate 10, which control may be needed when the sole plate 10 is to be heated to a relatively low ironing temperature, whereas the flatiron stand 60 is useful when the flatiron is not to be actively used for extended periods during ironing.
More specifically, the flatiron 6 includes the same basic elements as does the flatiron 5 of FIG. 1; however, the bore 23 in the heat storage element 20 is larger than the diameter of the control rod 31, such that the control rod slidingly extends therethrough, and the control rod 31 is instead threadingly engaged in a bore of an intermediate element 45 which is positioned between the heat storage element 20 and the sole plate 10. This intermediate element 45 has a flat bottom face 46 and a flat top face 47, as well as a hat portion 48 which is shaped to fit within the cavity 22 in the heat storage element 20. The lowermost tip of the control rod 31 terminates in the cavity 49 formed in the hat portion 48. The intermediate element 45 also includes a number of through-openings 50 and associated bimetallic lamella 51, the first ends of which are fixedly connected in the intermediate element and the second ends of which can move within the through-openings.
The flatiron also includes a number of flexible suspension elements 55 (only one shown in FIG. 2) which suspend the heat storage element 20 from the roof 16 of the hood 15. In addition, a heat storage quantity selector 36, which is connected between the heating rod 35 and the electrical plug 38, is mounted on the top face 24 of the heat storage element 20. This heat storage quantity selector 36 includes an adjustment knob 37 which extends through a hole 19 in the roof 16 of the hood 15 to enable the user of the flatiron to predetermine the quantity of heat to be stored in the heat storage element 20.
The flatiron stand 60 on which the flatiron is positionable includes a floor 61, feet 62 located at the periphery of the floor 61, and electrical socket 70 which is supplied with electrical power by a tripolar cable TC. The floor 61 includes a number of through-openings 63 and associated bimetallic lamella 64, the first ends of which are fixedly connected to the floor 61 and the second ends of which mount rollers 65 which are free to move in these through-openings, depending on the degree of bend in the associated bimetallic lamella. This bending will in turn be based on the temperature of the floor 61.
Operation of this embodiment of the inventive flatiron occurs as follows. The user sets both of the knobs 32 and 37 to the desired settings and connects the electrical plug 38 to a suitable electrical socket until the amount of heat stored in the heat storage element 20, as selected by knob 37, is achieved, at which time the heat quantity selector 36 will switch off the current to the heating rod 35 and the user will manually disconnect the flatiron from the electrical socket. During this time, and because the heat storage element 20 will have initially been in full contact with the flat top face 47 of the intermediate element 45 and the flat bottom face 46 of the intermediate element 45 will have initially been in full contact with the flat top surface 11 of the sole plate 10, the sole plate 10 will be heated up due to heat conduction. Concurrently the bimetallic lamella 40 and 51 will start to bend, and eventually they will respectively cause the intermediate element 45 to be moved out of contact with the sole plate 10 and the heat storage element 20 to be moved out of contact with the intermediate element 45. The intermediate element will then act to reduce the heat transfer from the heat storage element 20 to the sole plate 10. This is important in situations wherein the temperature selected by the temperature selector 30 for the bottom plate 10 is relatively low and the heat radiated by the heat storage element 20 towards the sole plate 10 would be greater than that which would have to be dissipated by the sole plate 10 in order to maintain its selected temperature.
When placed on the flatiron stand 60, if the sole plate 10 is not too hot, the flat bottom surface 12 will contact the floor 61 such that heat will be removed from the sole plate 10, thereby allowing it to be rested thereon during ironing. Once it reaches a higher temperature, the bimetallic lamella 64 will heat up and bend until the rollers 65 on their second ends extend upwardly above the floor 61 so as to support the sole plate 10 above the floor 61.
Turning now to the flatiron embodiment shown in FIGS. 3-6, generally indicated in FIG. 5 by the numeral 7, it is seen to include a bottom plate 10, a protective hood 15 and a heat storage element 20; however, the hood 15 includes no openings therein, such that the chamber C formed between the hood 15 and the bottom plate 10 will be a sealed chamber, and the sealed chamber is in fact evacuated when the flatiron is constructed.
The top surface 11 of the sole plate 10, instead of being entirely flat, includes a number of projections 10a which extend upwardly into the chamber C, each projection having a flat upper end surface facing the bottom face 21 of the heat storage element 20. Located in the areas between the projections 10a are insulating foils 70. These insulating foils will reflect any heat radiated from either the heat storage element 20 or the sole plate 10. As shown in FIG. 3, the topmost foil of the insulating foils 70 can be positioned between the flat upper end surfaces of the projections 10a and the bottom face 21 of the heat storage element 20. This foil will readily transmit heat from the heat storage element 20 to the projections 10a of the sole plate 10 when pressed therebetween, but will reflect any radiated heat from the portions thereof not in physical contact with either element. Additional insulating foils 71 extend upwardly from the sole plate 10 to enclose the sides and most of the top face of the heat storage element 20 and to reflect the heat radiated therefrom.
A heat-resistant control rod 81 of a temperature selector 80 slidingly extends through a bore 23 in the heat storage element 20, the lowermost tip being capable of extending beyond a step 21a of the heat storage element which extends away from the bottom face 21, and the uppermost end being in abutting relationship with the free end of a spring 82. The opposite end of the spring 82 is fixedly attached to the hood 15 by a mount 83. The lower end of a threaded adjustment pin 84, which extends through a threaded bracket 85 located in the chamber C about the sole plate 10, contacts the upper side of the spring 82, and the upper end of the pin 84 is fixedly connected to a magnetized head 86 which fits within a protruding portion 15a in the roof 16 of the hood 15. A magnetized knob 87 is positioned around this protruding portion 15a. The elements 81-87 form the temperature selector 80 for the flatiron. The rotation of the magnetized knob 87 causes the magnetized head 86 to rotate (note: the hood 15 is composed of a non-magnetic material), and thus the downward force on the control rod 81 is adjustable. This in turn controls the temperature to which the bimetallic lamella 40 must be heated before its second end will push the control rod 81 upwardly sufficiently that it will contact the step 21a of the heat storage element 20 and push it out of contact with the uppermost insulating foil, which is itself in contact with the flat upper end surfaces of the projections 10a.
Furthermore, a generally cylindrical element 91 of a snap-placement mechanism 90 is connected to the top face 24 of the heat storage element 20 so as to surround the control rod 81, this element 91 being connected to a mount 93 located in chamber C above the sole plate 10 by a spring 92 and to the movable head 95 of a mount located in the chamber C above the sole plate 10 by a spring 94. The movable head 95 is itself further supported by one end of a spring 97, the opposite end of which is connected to a mount 98 located in the chamber C above the sole plate 10. Elements 91-98 form the snap-placement mechanism 90 which causes the heat storage element 20 to be either positioned in a first position very close to the sole plate 10, i.e., such that it contacts the uppermost insulating foil 70 and presses it against the flat upper end surfaces of the projections 10a, or else is in a second position located at a predetermined distance away therefrom. In this regard, when the flatiron is made ready for initial use (the heat storage element 20 being cold (room temperature)), the snap-placement mechanism 90 will have caused the heat storage element 20 to be in its first position close to the sole plate 10 as indicated in FIG. 3 (note, however, that in FIG. 3 the heat storage element 20, the top insulating foil 70 and the flat upper end surfaces of the projections 10a are shown to be spaced apart from one another for enhanced clarity). When the flatiron is then connected to a source of electrical power, the heating rod 35 in the heat storage element 20 will cause the heat storage element 20 to heat up, and as this occurs heat will pass by conduction through the uppermost insulating foil 10 and into the projections 10a, and thus the temperature of the entire sole plate 10 will rise. Eventually the free end of bimetallic lamella 40 will bend away from the top surface 11 of the sole plate 10 and it will eventually push the rod 81 and then the heating element 20 away from the sole plate 10. At a certain point, the springs 92, 94 and 97 of the snap-placement mechanism 90 will cause the generally cylindrical element 91 (and thus the heat storage element 20 as a whole) to snap quickly further away from the sole plate 10 and into its second, predetermined position away from the sole plate 10. At this point the forces acting on the rod 81 by the bimetallic lamella 40 and the spring 82 (this force being adjustable via pin 84) will be in balance. With the passage of time and as the flatiron is used the sole plate 10 will cool, and the free end of the bimetallic lamella will bend back towards the top surface 11 of the sole plate 10. Concurrently the spring 82 will cause the pin 81 to move towards the sole plate 10. At a certain point a cross bar portion 81a of the control rod 81 will contact the top surface of the heat storage element 20 and cause it to also move towards the sole plate 10. Eventually the snap-placement springs 92, 94 and 97 of the mechanism 90 will cause the generally cylindrical element 91 (and thus the heat storage element 20) to snap quickly back to its initial, first position very close to the sole plate 10 (see FIG. 3).
It should be noted that electrical power can be supplied to the heating rod 35 via the various elements in the rear end of the flatiron as shown in FIGS. 4-6.
FIG. 4 shows in detail electrical socket 100 which can be mounted on the handle H of the inventive flatiron shown in FIG. 3 for cooperation with an external electrical plug P. The electrical socket includes a cylindrical wall 101, one end of which forms a mouth M for insertion of the plug P, and located within the wall 101 are fixed plates 102 and 105, as well as movable plates 108, 111 and 114. Fixed plate 102, being the farthest from the mouth M, includes two wire holes 103 (only one shown in FIG. 4) through which the two electrical wires for the heating rod 35 in the heat storage element extend, and an abutment stop 104 which extends towards the mouth M. Fixed plate 105, which is located closer to the mouth M, includes two pin holes 106 (only one is shown in FIG. 4) and a central opening 107. The first movable plate 108, which is positioned between the fixed plate 102 and a stop ridge 101a which extends inwardly from the cylindrical wall 101, includes two connector terminals 109 (only one is shown in FIG. 4) and an abutment block portion 110 in its center. The second movable plate 111, which is positioned between the first movable plate 108 and the fixed plate 105, includes two electrical pins 112 which extend through the pin holes 106 in the fixed plate 105 and an abutment block portion 113 in its center. The third movable plate 114, which is positioned between the fixed plate 105 and the mouth M, includes two pin holes 115 and an abutment stop 116 which extends towards the abutment stop 104 of the fixed plate 102. A first coiled spring 118 extends between the abutment stop 104 and the abutment block portion 110 of the first movable plate 108, a second coiled spring 118b extends between the abutment block portion 113 of the second movable plate 111, and a third coiled spring 118c extends from the abutment block portion 113 of the second movable plate 111, through the central opening 107 in the fixed plate 114, and to the abutment stop 116 of the third movable plate 114. As the plug P is inserted into the mouth M of the cylindrical wall 101 of the socket 100, the three movable plates 108, 111 and 114 are pushed towards the fixed plate 102 against the force of springs 118a, 118b and 118c until the electrical pins 112 come into contact with the connector terminals 109 on the first movable plate 108 so as to allow electricity to flow from the electrical pins 112 to the connector terminals 109, and thereafter through the wires W which extend through the wire holes 103 and connect to the heating rod 35.
It can also be seen from FIG. 4 that the electrical socket 100 includes a control mechanism which is attached to the outside of the cylindrical wall 101, the control mechanism including a housing 121 which includes a movable lock element 122 that can move within an electrical coil 124 towards and away from the cylindrical wall 101 such that the head 123 thereon can extend through an opening in the cylindrical wall 101 to project into the interior of the cylindrical wall 101 at a location between the fixed plate 105 and the mouth M. A spring 125 biases the head 123 towards the cylindrical wall 101. Once the plug P has pushed the movable plate 114 over and past the head 123 into the plug 100, the head 123 will lock the movable plate 114 in this retracted position within the socket 100 and thus allow the electrical current to flow from the plug P through the electrical pins 112 until an electrical signal is received in coil 124 via line 146, at which point the lock element 122 will be moved away from the cylindrical wall 101. The head 123 will move out of the interior of the socket 100, releasing the movable plate 114. The springs 118a, 118b and 118c will then cause the movable plate 114 to move the plug P out of the socket 100.
Referring now in more detail to the showings in FIGS. 5 and 6, the rear end of the flatiron is seen to include a handle H (the mounting of the socket 100 thereon is not indicated). In this flatiron one end of a bimetallic spring 130 is attached to the heat storage element 20 and the opposite (free) end, which mounts a ferro-magnetic block 131, is located near the inside surface of the rear side 18 of the hood 15. At the same time, an indicator device 140 is attached to the outside surface of the rear side of the hood 15, the indicator device including an elongated housing 141 which is located (see FIG. 5) on the rear side 18 of the hood 15 and oriented so as to extend in the same direction that the magnet 131 is moved by the spring 130 as it is heated and cooled, a magnet 142 which is slidable within the housing 141, and two electrical contacts 143, 144 which are movably located within the housing 141, by a handle 145. As the heat storage element 20 heats up, the bimetallic spring 130 will bend, thereby causing the ferromagnetic block 131 and consequently the magnet 142 to move within the housing 141. Once the magnet 142 pushes the electrical contact 143 into engagement with electrical contact 144 (the positioning of the electrical contacts 143 and 144 being determined by the handle 145), an electrical signal will flow through the wires 146 to coil 124 (see FIG. 4), thus allowing the springs 118a, 118b and 118c to disconnect the plug P from the socket 100 as noted above.
Although a number of embodiments of the inventive flatiron have been discussed in detail, it will be obvious the numerous modifications therein can be made and still fall within the scope of the appended claims. | A cordless flatiron includes a sole plate with an exposed bottom surface forming an ironing surface and a top surface including a number of projections extending upwardly therefrom. A protective hood attached to the periphery of the top surface of the sole plate forms an evacuated, sealed chamber thereabove and a heat storage element is positioned in the chamber so as to be movable toward and away from the projections of the sole plate. The heat storage element is heated by an electric heating rod extending therein. A temperature responsive regulator element positioned between the heat storage element and the top of the sole plate and responsive to the temperature of the sole plate is arranged by its configuration to position the heat storage with respect to the upper ends of the projections of the sole plate and thus determine whether or not heat is conducted from the heat storage element to the projections of the sole plate and to the ironing surface of the sole plate. An adjustable temperature selector is provided for selecting the temperature of the sole plate and an adjustable heat quantity selector provides for switching off the current to the heating rod (when the flatiron is connected to an electrical power supply) based on the temperature of the heat storage element. A reflective foil heat radiation barrier is positioned between the sole plate and heat storage element to shield the sole plate from heat radiation from the heat storage element and to limit transfer of heat from the heat storage element to the soleplate essentially to that transmitted through the projections. | 3 |
CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] Priority is claimed to German Application No. DE 10 2010 048 187.4, filed on Oct. 13, 2010, the entire disclosure of which is incorporated by reference herein.
FIELD
[0002] The invention relates to a method and an apparatus for monitoring the maximum available capacity of a battery and to an uninterruptible power supply, which is equipped with an apparatus for monitoring the maximum available capacity of a battery.
BACKGROUND
[0003] In order to provide an uninterrupted power supply, operation by means of batteries, in particular rechargeable batteries, is provided besides mains operation, in case of breakdown. For being able to provide a reliable electric power supply in industrial plants, motor vehicles, and many other fields, it is necessary to monitor the state of health (SOH) of the battery, the currently available or actual battery capacity, the charge status of the battery and numerous other battery parameters. Numerous solution options are already known in this regard.
[0004] For example, DE 199 52 693 A1 describes an apparatus for the determination and display of the state of health of a battery. In particular, the charge status of a battery can be determined with the known apparatus. To this end, the apparatus is equipped with sensors for ascertaining the battery voltage, battery temperature and battery current (charging current or discharging current). The known apparatus is further equipped with an analysis circuit, which can determine the battery SOH from the measured values. The known apparatus is furthermore capable of determining a charging and/or discharging balance of the battery for determination of the energy flow as a function of the discharge depth. In this connection, the battery temperature is one of the factors considered.
[0005] In addition, a method of monitoring rechargeable batteries is described in DE 38 32 839 C2. The method serves inter alia for calculation of the capacity that can be withdrawn from a battery for various discharging currents in relationship to the associated values of the discharge characteristic. In this manner, the point when the extractable capacity for an intended discharging current falls below a permissible minimum value can be established. This method takes account of the ‘Peukert effect’, which states that, as the discharging current of a battery increases, the energy that can be withdrawn steadily decreases.
[0006] A method for determining the status of a battery is described in DE 40 07 883 A1 with which method a respective discharge voltage value measured after current extraction from the battery is compared with a voltage value which is determined from a series of charge status curves, and the voltage difference of the two values is determined. This voltage difference is compared with the stored characteristics of the particular battery type and the decrease of the maximum available battery capacity is hence determined.
[0007] A monitoring and controlling system for several batteries connected in series is described in DE 10 2007 029 156 A1, the batteries potentials thereof being tapped and evaluated in order to optimize the service life or duration of batteries in hybrid vehicles.
SUMMARY
[0008] The present invention provides a method of monitoring a maximum available capacity of a battery. The method includes:
a) providing a plurality of diverse end-of-discharge-voltage values; b) assigning a counter to each of the plurality of diverse end-of-discharge-voltage values; c) discharging the battery; d) determining one of the plurality of end-of-discharge-voltage values at which the battery is discharged; e) incrementing a counter reading of the counter assigned to the determined end-of-discharge-voltage value; f) repeating steps c-e; g) reading-off the counter readings so as to obtain a plurality of read-off counter readings; and h) determining, based on the plurality of read-off counter readings, a first factor representing a first measure of a decline in the maximum available battery capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
[0018] FIG. 1A and 1B shows a flowchart illustrating the charge balancing and determination of the battery quality;
[0019] FIG. 2 shows an embodiment of the invention providing an uninterruptible power supply.
DETAILED DESCRIPTION
[0020] In an embodiment, the present invention provides a method and an apparatus with which the currently determined or actual charge status of a battery can be more accurately determined in order that, by this method, precise predictions as to the anticipated remaining operating time of the battery can be provided.
[0021] An embodiment of the invention provides a method by which the currently determined or actual battery quality can be checked at predetermined time points. The battery-quality value provides information as to the size of the maximum available battery capacity in relationship to the nominal capacity. The term nominal capacity refers to the maximum electrical charge that can theoretically be stored in the battery. Conversely, the term maximum available capacity refers to the quantity of charge that represents the maximum that can actually be withdrawn from the battery. The maximum available battery capacity depends on numerous factors, such as the battery temperature, the service life or duration and the internal resistance of the battery.
[0022] In an embodiment, the present invention can preferably be used in industrial systems in which UPS (Uninterruptible Power Supply) devices are employed. UPS devices serve, in the event of a power failure, to enable parts of the system and the control thereof to continue to operate for a certain period and then to be closed down in a defined manner. A precise knowledge of the currently measured or actual battery operating time is necessary because, if calculation of the battery operating time is defective, the battery voltage of the UPS can fail before the consumer unit has been shut down.
[0023] Accordingly, it is advantageous to know the actual charge status and the actual power consumption during battery operation in order to make accurate predictions as to the anticipated remaining battery operating time. A prediction of this kind enables the continued operation of the system, by means of the UPS devices used, for a specific period following a power failure, which may in fact correspond with the maximum operating time, in order that sufficient battery power is still available to enable the consumer units to be safely closed down. The actual charge status can be determined by means of a charging and discharging balance.
[0024] Since, in order to obtain a precise charge balance, the actual capacity of the battery, i.e. the maximum available capacity, needs to be accurately known, a method of monitoring the maximum available capacity of a battery is made available according to the invention.
[0025] According to an embodiment of the invention, a plurality of diverse values are provided for the end-of-discharge voltage at the end of each current extraction, to each of which values a counter is assigned. Current is then extracted from the battery and the value of the respective end-of-discharge voltage at which the battery became discharged is determined. The counter reading for the counter assigned to the determined end-of-discharge-voltage value is then incremented. The above-mentioned method steps are repeated for each further discharging process. At a predetermined point in time, the counter reading of each counter is read off. A first factor representing a measure of the decline in maximum available battery capacity is determined as a function of the read-off counter readings. It should be noted that current extraction or discharging processes are not enforced especially for measurement purposes, but arise as a result of normal battery operation.
[0026] In an embodiment, because a plurality of end-of-discharge-voltage values are included, the diminution in the maximum available capacity of a battery can be determined more precisely as a function of the discharge depth of a discharging process.
[0027] As already mentioned above, the maximum available battery capacity needs to be accurately known in order to obtain the actual battery charge status.
[0028] One option for determining the first factor consists in establishing, for each battery type to be monitored, measurement series which exhibit the various end-of-discharge-voltage values as parameters and which are plotted over the number of discharging processes. In this case, a particular value, which indicates the extent to which the maximum available capacity has declined relative to the nominal capacity, is associated with each counter reading for an end-of-discharge-voltage value at the end of each current extraction.
[0029] In order to be able to indicate the battery quality, i.e. the value of the decline in maximum available battery capacity relative to the nominal capacity, even more precisely, the battery temperature is measured and the counter reading of the respective counter is incremented with temperature-weighting.
[0030] The degree of temperature-weighting can be read off for the respective battery type from various series of measurements that have been generated for various battery temperatures.
[0031] In an embodiment, the maximum available battery capacity can be determined even more accurately by measuring the battery temperature and the service life or duration of the battery. Determined then from the measured battery temperature and the measured service life or duration is a second factor, which is a further measure of the decline in maximum available battery capacity. It should be noted at this point that the measured service life of the battery allows conclusions to be drawn as to its durability.
[0032] In order to obtain even more precise information as to the maximum available battery capacity, the internal resistance of the battery is determined. A third factor, which represents a further measure of the decline in maximum available battery capacity, is determined as a function of the established internal resistance.
[0033] In order to determine the actual charge status of the battery, a charging-current and discharging-current balancing operation, or charge balancing for short, is performed. Charge balancing methods that are known per se may be used for this purpose. If, in addition, the actual discharging current is measured during battery operation, the anticipated battery operating time can be determined as a function of the actual charge status, the actual discharging current and the maximum available battery capacity. Owing to such measures, it is possible to continue operating the system, by means of the UPS devices used, for a specific period following a power failure, which may even correspond with the maximum operating time. In addition, it is thereby ensured that, on expiry of the maximum operating time, a sufficiently high battery power to safely close down the consumer units is still available.
[0034] For the charging- and discharging-current balancing operation, the characteristic values selected for the battery type to be monitored are used together with the measured actual battery current, the actual battery temperature and/or the actual battery voltage in order to determine therefrom the actual charge status.
[0035] The characteristic values of the battery may refer to the nominal voltage, the durability, the nominal capacity, the internal-resistance characteristic, the thermal behaviour and other parameters. These values are determined in advance with the aid of numerous series of measurements, and are taken into consideration when implementing the method.
[0036] In an embodiment, an apparatus for monitoring the maximum available capacity of a battery is provided. The apparatus is equipped with a memory device in which a plurality of diverse ranges for end-of-discharge-voltage values are made-up. The apparatus is further equipped with a plurality of counters, which are respectively assigned to one of the ranges of the end-of-discharge-voltage values. A control and analysis device is designed to determine the range of the end-of-discharge-voltage value at which the battery has become discharged at the end of each current extraction to control the incrementation of the counter reading of the counter assigned to the currently determined end-of-discharge-voltage value, to read off the counter reading from each counter and to determine, as a function of the read-off counter readings, a first factor, which represents a measure of the decline in maximum available battery capacity.
[0037] In an embodiment, in order to be able to provide more precise information as to the decline in maximum available battery capacity, a temperature detector to measure the actual battery temperature and a device to measure the service life of the battery are provided. The control and analysis device is designed in a manner such that it can determine from the measured battery temperature and the measured service life a second factor, which represents a further measure of the decline in maximum available battery capacity.
[0038] The control and analysis device is also capable of determining the internal resistance of the battery in order to define a third factor as a function of the determined internal resistance, which third factor represents a further measure of the decline in maximum available battery capacity.
[0039] In order to be able to provide precise information as to the actual available maximum battery capacity, the control and analysis device can determine the maximum available battery capacity as a function of the first and second and/or third factors.
[0040] In order to determine the actual charge status of the battery, the apparatus is equipped with a further memory device to store the characteristic values of the battery, a voltage detector to detect the actual battery voltage, and a current detector to detect the actual battery current. The control and analysis device is furthermore designed to execute a charge balancing operation.
[0041] The apparatus according to the invention for monitoring the maximum available capacity of a battery is integrated into a mains for uninterrupted power supply of a consumer unit.
[0042] It should be noted that the items of information used to define the actual capacity of the battery can be determined during operation of the UPS device. In other words, the battery is in this case permanently connected to the UPS device.
[0043] FIG. 2 shows an example of a UPS device 30 , i.e. an uninterruptible power supply, which contains a rechargeable battery 110 . By means of the UPS device 30 , electrical appliances or systems can, in the event of a power failure, continue to be supplied with power on a temporary basis and then safely closed down. To monitor the battery 110 , the UPS device 30 is equipped with a plurality of sensors or detectors, such as a voltage detector 60 , a current detector 70 and a temperature detector 80 . The voltage detector 60 measures the actual battery voltage at settable time points or continuously. The current detector 70 measures the actual battery current at settable time points or continuously. Depending on battery operation, the battery current will correspond with the discharging current or charging current. The temperature detector 80 measures the battery temperature at settable time points or continuously. The measured values from detectors 60 , 70 and 80 are supplied to a control and analysis device 40 . A memory 90 is provided in which a plurality of diverse ranges of end-of-discharge-voltage values, taken at the end of each current extraction, are made up. As described in greater detail below, the ranges of the end-of-discharge-voltage values serve for determination of the discharge depth of the battery 110 in relation to each discharging process.
[0044] Further provided is a memory 100 , in which the characteristic values of the battery 110 are stored, e.g. during the initialisation phase. It should be noted that the characteristic values of the battery stored in the memory 100 have been determined in advance by means of a series of measurement cycles on a battery type that corresponds with battery 110 . The contents of memories 90 and 100 can be read by the control and analysis device 40 . The results determined by the control and analysis device 40 can be visually output via a display device 50 . Further connected to the control and analysis device are a plurality of counters 120 , 130 , which are assigned respectively to one of the ranges of the end-of-discharge-voltage values made up in memory 90 . This assignment is known to the control and analysis device.
[0045] The charge balancing and monitoring of the battery quality performed by the control and analysis device 40 is explained in greater detail below by reference to the flowchart shown in FIG. 1A and 1B . The charge-balancing algorithm represented by way of example in the flowchart can be executed by the control and analysis device 40 .
[0046] Let us firstly assume that the charge balancing with regard to battery 110 is to be undertaken for the first time. At the start of balancing, represented in FIG. 1A by the step ‘Initialisation’, the control and analysis device 40 is firstly initialised. To this end, all characteristic values of the battery are input and stored in the memory 100 . If, on initial startup, the charge status of the battery 110 is unknown, the actual charge of the battery 110 is set at 25% in step 1 . It is ensured in this manner that an immediate battery operation of the UPS device 30 is possible. Furthermore, the battery capacity, which below means the maximum available battery capacity, is set at the equivalent of the nominal capacity. At step 2 , measurement begins of the battery current, battery voltage and battery temperature by the current detector 70 , the voltage detector 60 and the temperature detector 80 respectively. The actual measured values are supplied to the control and analysis device 40 by the detectors 60 to 80 . As shown in step 3 of the flowchart, the control and analysis device 40 determines correction values for the actual charge, which was set at 25% at the start, from the battery characteristic values stored in the memory 100 and from the actual measured values supplied by the detectors 60 to 80 . The control and analysis device 40 can use appropriate characteristic values stored in the UPS device 30 for determination of the correction values. The correction values and measured values are updated in each charge-balancing cycle.
[0047] Let us now assume that the control and analysis device 40 has established at step 4 that the balancing cycle currently relates to a charging operation, so the UPS device is being mains operated. In this operating mode, the battery 110 is charged up via the mains voltage. The battery current measured at step 2 thus corresponds to the actual charging current of the battery. Consequently, the control and analysis device 40 recognises at step 5 that a charging current is flowing and the balancing algorithm branches off to step 6 . Taking account of the values measured at step 2 and the correction values determined at step 3 , the amount of additional charge the battery has received at this time is calculated within the actual balancing cycle. The actual charge, which had previously been set at 25%, is incremented by this value. The balancing algorithm then continues to step 7 and the control and analysis device 40 checks whether the actual battery charge has reached 100%. To this end, the control and analysis device 40 checks whether the battery-charging current measured at step 2 has fallen below a specific threshold value. In the present example, the control and analysis device 40 recognises at step 7 that the battery is not yet fully charged, and the charging operation is continued. As a consequence, the balancing algorithm jumps back to step 2 .
[0048] Again, the actual measured values from detectors 60 , 70 and 80 are input by the control and analysis device. At step 3 , the correction factor for the actual charge is again determined, depending on the actual measured values and the characteristic values of the battery.
[0049] Let us assume that the charging current measured by the current detector 70 has still not fallen below the predetermined threshold value, so that, at steps 4 and 5 , the control and analysis device 40 answers the queries respectively with ‘yes’. Consequently, the amount of charge by which the battery charge is to be increased will again be measured at step 6 , using the measured values measured by the detectors 60 to 80 and the correction values determined at step 3 .
[0050] At step 7 , the control and analysis device 40 now recognises that the battery is fully charged. The balancing algorithm therefore branches off to step 8 . At step 8 , the control and analysis device 40 terminates the charging operation. Since the charging current measured by the current detector 70 has fallen below the defined threshold, the control and analysis device 40 answers the query at step 5 with ‘no’. Consequently, the control and analysis device 40 terminates the charging operation. Conversely, the mains operation at step 4 continues. The actual charge status continues to be monitored by means of the balancing algorithm.
[0051] Let us now assume that due to a mains breakdown, the mains operation is terminated at step 4 . The UPS device 30 is to be operated in current extraction or discharging mode from the battery. The voltage detector 60 again determines the actual battery voltage, the current detector 70 determines the actual battery current, and the temperature detector 80 determines the actual battery temperature. The battery current measured by the current detector 70 now corresponds with the actual or currently measured discharging current. At step 3 , as described above, correction factors are determined in the control and analysis device 40 using the actual measured values and the characteristic values. The balancing algorithm now branches off from step 4 to step 9 . The correction values are used together with the actual measured values at step 9 for calculation of the amount of charge that the battery has lost in the actual balancing cycle. The actual charge of battery 110 is decremented by this value.
[0052] It should be noted at this point that, according to the Peukert effect, the discharging current measured by current detector 70 in battery operation determines the maximum withdrawable charge from battery 110 . The control and analysis device 40 is designed to provide, as a function of the currently determined charge status of the battery and the currently measured discharging current, a prediction as to the battery operating time in battery operation or discharging mode. The relevant value can be shown on the display 50 .
[0053] At step 10 , the control and analysis device 40 checks whether the currently calculated charge is greater than the provided remaining charge for shutting down the consumer unit, symbolized with “>0%” in FIG. 1A . If so, the balancing algorithm branches off to step 11 .
[0054] At step 11 , the control and analysis device 40 checks whether the actual battery voltage has fallen to the lowest end-of-discharge voltage. If so, the battery is assumed to be charged with the provided remaining charge, and the consumer unit is shut down. This also takes place, if the provided remaining charge is reached in step 10 . If, however, the voltage has not fallen below the lowest end-of-discharge voltage, the battery 110 can continue being discharged, and the balancing algorithm jumps to step 2 . The UPS device 30 can consequently operate in discharging operation as before. If, however, the control and analysis device 40 finds at step 11 that the actual battery voltage measured by the voltage detector 60 is smaller than the lowest end-of-discharge voltage, the discharging process is terminated in so far as only the consumer unit is shut down. The control and analysis device 40 can output on the display device 50 the relevant information that the UPS 30 is no longer operationally ready.
[0055] Thus, the control and analysis device 40 is designed in a manner such that, as a function of the currently determined battery charge, it initiates the shutdown of a consumer unit connected to the UPS device 30 in sufficiently good time for it to be safely closed down. Only after the shutdown should the actual battery voltage fall below the end-of-discharge voltage.
[0056] When mains operation begins again, the control and analysis device 40 ensures that the battery 110 is connected to the mains voltage supply and is charged.
[0057] In order to be able to determine the actual charge status of the battery 110 , and to derive therefrom a prediction as to the actual battery operating time, the control and analysis device 40 can determine the battery quality. By contrast with charge balancing, which is advantageously undertaken cycle-by-cycle, the actual battery quality can be checked at longer, parameterisable intervals. The battery quality is defined by a value which indicates how great the maximum available battery capacity is relative to the nominal capacity. If, for example, the battery capacity falls below a value of 80%, the battery 110 is deemed to be non-useable. Information to this effect can be shown by the control and analysis device 40 via the display device 50 .
[0058] The check of battery quality, or of maximum available battery capacity, starts at step 14 of the flowchart shown in FIG. 1B . At step 14 , which may be optional, the control and analysis device 40 determines the service life of the battery. Measurement of the service life can take place permanently. Taking account of the currently measured battery temperature by the temperature detector 80 , and the measured service life, a temperature-weighted factor representing a measure of the falling value of the maximum available battery capacity is determined. To this end, the control and analysis device 40 can have recourse to appropriate characteristic values that indicate a loss factor as a function of the service life of the battery, or its durability, and the currently measured battery temperature. The correction of the maximum available battery capacity is undertaken at step 15 .
[0059] At step 16 , the control and analysis device 40 permanently monitors the charge balancing as to when a current extraction from the battery, i.e. a discharging process has been terminated. If a discharging process has been terminated, the control and analysis device 40 determines the respective end-of-discharge voltage at which the battery 110 became discharged in the respective discharging process and assigns such discharge voltage into its range of discharge voltage values. To this end, the control and analysis device 40 is connected to an appropriate number of counters 120 to 130 , each of which is assigned to one of the ranges of the end-of-discharge-voltage values made up in the memory 90 . Every discharging process detected by the control and analysis device 40 is thus counted in the respective counter as a function of the respective end-of-discharge-voltage value detected. The control and analysis device 40 can have recourse to appropriate characteristic values, which provide an appropriate value for every counter value and for every end-of-discharge-voltage value in relation to the battery type used. As a function of the counter readings of counters 120 , 130 , the control and analysis device 40 then determines a factor which is again a measure of the decline in maximum available battery capacity. In addition, the control and analysis device 40 can also take account of the currently measured battery temperature during a discharging process in order to increment the counter reading of the respective counters 120 and 130 with temperature weighting.
[0060] The control and analysis device 40 can then determine, from the temperature-weighted counter readings, an even more precise value for the battery quality, or the maximum available battery capacity. The relevant calculation of the maximum available battery capacity is undertaken at steps 16 and 17 .
[0061] A further measure of the decline in maximum available battery capacity can be determined from the dynamic internal resistance of the battery 110 . Numerous methods of calculating the internal resistance of the battery are known.
[0062] In the present example, the dynamic internal resistance can be measured at step 18 as follows: firstly, let us assume that the dynamic internal resistance of the battery 110 is measured with a fully charged battery and with temperature compensation. According to a first measurement method, a small alternating voltage with constant frequency, e.g. 100 Hz, is imposed on the battery voltage and the battery alternating current is then measured by the current detector 70 . The internal resistance can then be calculated by the control and analysis device 40 according to the equation R I =U EFF /I EFF .
[0063] According to an alternative measurement method, two direct currents are successively withdrawn from the battery 110 and the relevant battery voltages are measured therefrom. The internal resistance is derived according to the equation R I =ΔU/ΔI. In order to eliminate temperature influences on the internal resistance, the measured value of the internal resistance, together with the measured value for the actual battery temperature, is converted to a resistance value at a standardised temperature. These standardised resistance values are comparable one with another. In order to assess the measured internal resistance in respect of its influence on the maximum available battery capacity, it is necessary to measure and store a reference value in the brand new condition of battery 110 . A measure of the declining battery capacity is now derived from the increase in internal resistance.
[0064] At step 19 , the maximum available battery capacity is then corrected for the changes in internal resistance.
[0065] It should be noted at this point that the generation of the characteristic values necessary for calculating the correction factors for the battery capacity and for the actual charge status of the battery 110 are not part of the subject-matter of the invention and will therefore not be described in greater detail.
[0066] At the end of the battery quality check, the algorithm jumps to step 2 and the above-described charge-balancing process starts afresh.
[0067] While the invention has been described with reference to particular embodiments thereof, it will be understood by those having ordinary skill the art that various changes may be made therein without departing from the scope and spirit of the invention. Further, the present invention is not limited to the embodiments described herein; reference should be had to the appended claims. | A method of monitoring a maximum available capacity of a battery includes:
a) providing a plurality of diverse end-of-discharge-voltage values; b) assigning a counter to each of the plurality of diverse end-of-discharge-voltage values; c) discharging the battery; d) determining one of the plurality of end-of-discharge-voltage values at which the battery is discharged; e) incrementing a counter reading of the counter assigned to the determined end-of-discharge-voltage value; f) repeating steps c-e; g) reading-off the counter readings so as to obtain a plurality of read-off counter readings; and h) determining, based on the plurality of read-off counter readings, a first factor representing a first measure of a decline in the maximum available battery capacity. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The purpose of this invention is to provide an effective method of incorporating liquid polysaccharides which are normaly sticky into a product while avoiding the problem of stickiness. This invention thus describes hydrated polymeric compositions containing honey which may be utilized to treat keratinous substrates such as skin and hair.
2. Description of the Art Practices
Pure natural honey contains sugar secretions and are collected from honeycombs. Honey also contains natural proteins, minerals, vitamin B1, vitamin B2, vitamin C, and nicotinic acid all of which makes honey desirable for use as a natural ingredient for cosmetics. Honey has been used as a fragrance ingredient and humectant in skin conditioners. Honey has also been employed as a biological additive in shampoos, face, body and hand creams and lotions; bath products, hair conditioners, cleansing products, moisturizing creams and lotions, and in paste masks (mud packs).
Honey is typically used at very low levels in cosmetic products due to an undesirable stickiness associated with the presence of a high level of solubilized polysaccharides. A feeling of tackiness results when pure natural honey is applied to keratinous substrates, such as skin or hair. Thus, the use of honey in significant quantities in cosmetic and toiletries has heretofore been limited.
U.S. Pat. No. 5,626,853 to Bara et al., issued May 6, 1997 relates to a gel containing an aqueous phase, a hydrophilic polymer as a gelling agent, a coloring material which is soluble or dispersible in the aqueous phase and at least one organopolysiloxane solubilized in the aqueous phase. The Bara et al., patent describes the gel as usable in the cosmetics field for making up both the face and the human body.
U.S. Pat. No. 5,688,831 issued Nov. 18, 1997 to El-Nokaly et al., describes a make-up composition in the form of a water-in-oil emulsion comprising a silicone phase, humectant, pigment and organic amphiphilic material capable of forming smectic lyotropic liquid crystals in the product or on the skin.
Clum et al., in U.S. Pat. No. 4,423,041 issued Dec. 27, 1983 describes a detackifying composition for use in emulsion-type personal care compositions comprising a mixture of a silicone fluid and a silicone wax in a ratio of from about 9:1 to 1:3. McAnalley, in U.S. Pat. No. 4,917,890 issued Apr. 17, 1990 discusses a process for producing aloe extracts including the separation of the leaves of the aloe plant into distinct portions.
U.S. Pat. No. 4,863,725 to Deckner issued Sep. 5, 1989 relates to a clear oil-free, non-greasy skin moisturizing composition which includes as the major component a copolymer of glycerol and methacrylic acid polyglycerylmethacrylate together with a polyol to enhance skin feel, one or more preservatives and water, and optionally one or more thickeners, one or more skin soothing agents, such as allantoin and/or dl-panthenol, one or more astringents, and/or one or more colorants.
Lee, in U.S. Pat. No. 5,501,849 issued Mar. 3, 1996 discloses an emollient composition, having a stated use in a method of treating a psoriasis in which abnormal skin is exposed to actinic or ultraviolet radiation, comprising a lipophilic emollient, wherein the composition is a non-viscous liquid which, on application to skin or a like surface, spreads to provide a substantially uniform coating of the lipophilic emollient, and wherein the coating does not absorb a significant amount of the incident actinic or ultraviolet radiation and is sufficiently non-volatile to persist for a period of sufficient length, for a therapeutically effective dose of incident radiation to be administered.
Ryklin et al., in U.S. Pat. No. 5,746,945 issued May 5, 1998 discusses water-in-oil emulsions which comprising (a) water; (b) from about 10 to 65% by weight of an oil; and (c) an emulsification system comprising a polysiloxane polyalkyl polyether copolymer and a phthalic anhydride derivative, substantially permanently maintaining the water and oil as an emulsion, the emulsification system and the emulsification system being substantially free from aluminum and zirconium salts, the emulsion being at a pH of from about 5 to 10.
U.S. Pat. No. 5,798,111 issued to Kanga et al., Aug. 25, 1998 describes clear emulsion cosmetic compositions that include an aqueous phase having 2-methyl-1,3-propanediol and an oily phase containing silicones, especially cyclomethicone and a cyclomethicone-dimethicone copolyol silicone fluid mixture. The compositions described by Kanga et al., are stated to exhibit visual clarity and can be formulated into a cold cream or antiperspirant/deodorant which are highly phase stable and insensitive to shear decomposition while being processed.
To the extent that the foregoing references are relevant to the present invention, they are herein specifically incorporated by reference. Where temperatures are given, they are in degrees Celsius unless otherwise indicated. Percentages and ratios given herein are by weight unless otherwise indicated. Measurements herein are stated in degrees of approximation and where appropriate the word “about” may be inserted before any measurement. Ranges and ratios maybe combined.
SUMMARY OF THE INVENTION
The present invention describes a composition of matter comprising polyglycerylmethacrylate; and, a liquid polysaccharide component.
The present invention further describes a composition of matter comprising polyglycerylmethacrylate; a liquid polysaccharide component; and, a silicone based component.
Yet a further aspect of the present invention is a composition of matter comprising polyglycerylmethacrylate; a liquid polysaccharide component; a silicone based component, and, a glycol.
The present invention also describes a substantially homogeneous hydrated honey gel polymeric composition prepared by the process of
(A) dispersing honey in polyglycerylmethacrylate,
(B) mixing the honey and the polyglycerylmethacrylate for a sufficient period of time to form a hydrated honey gel polymeric composition, and a process for preparing the same.
Further described herein is a process for preparing a substantially homogeneous hydrated honey gel polymeric composition by:
(A) dispersing honey in polyglycerylmethacrylate; and,
(B) mixing the honey and the polyglycerylmethacrylate to form a substantially homogeneous mixture,
(C) combining with the substantially homogeneous mixture a silicone based component, and
(D) mixing the resultant mixture for a sufficient period of time to form a substantially homogeneous translucent homogeneous hydrated honey gel polymeric composition.
DETAILED DESCRIPTION OF THE INVENTION
The first component of the present invention to be discussed is the polyglycerylmethacrylate component. The polyglycerylmethacrylate component is a highly crosslinked polymer.
The polyglycerylmethacrylate is in the form of a transparent gel containing from about 50 to about 75% by weight solids, and may or may not contain incidental ingredients, such as propylene glycol which may be present in an amount of 2% or less. A preferred polyglycerylmethacrylate is Lubrajel CG, a registered trademark of United Guardian Inc., which is distributed by International Specialty Products of Wayne N.J. The preferred form of Lubrajel CG has a viscosity at 20 degree C. (Brookfield RTV) ranging from about 400,000 to about 5,000,000, a specific gravity of 1.2 mg/ml, is completely soluble in water and is substantially stable at 250 degree. F., and on sealed storage for 3 years at 20 degree. C. Lubrajel CG is a clathrate formed by the reaction of glycerin and methylmethacrylate.
Lubrajel CG can best be described as a hydrated polymeric complex, the water of hydration of which is subject to change with the humidity of the atmosphere to which it is exposed. Lubrajel CG has been described as a clathrate formed by the reaction of sodium glycerate with a methacrylic acid polymer, stabilized with a small amount of propylene glycol.
Lubrajel CG is characterized by its non-allergenic properties and its excellent moisturizing qualities which have been confirmed by skin impedance measurements. The bound water in Lubrajel CG ranges from as little as one-third to as much as 58%. The free water ranges from 5-20%. The conversion of the clathrate to the hydrate causes a rapid drop in viscosity. When Lubrajel CG is diluted with water, the end result is largely free water, resulting in a drop in viscosity, depending upon the particular grade.
The liquid polysaccharide component is usually a sugar. A sugar being defined as a material having hydroxy, ketose, or aldose moieties and which is sweet to the taste. A preferred source of the liquid polysaccharide component is honey.
Honey consists chiefly of dextrose and levulose (70-80%) polysaccharides with smaller amounts of water, sucrose (2-10%), dextrin, wax, proteins, volatile oil, mineral acids, and coloring and flavoring components, based on derivative plant source. The polysaccharide in the liquid polysaccharide component is typically a mixture of levulose and dextrose.
Other sources of the liquid polysaccharide component includes corn syrup. The corn syrup contains glucose and fructose. In particular, high fructose corn syrup is preferred when corn syrup is employed. Mixtures of high fructose corn syrup and honey may be effectively utilized in the present invention.
Volatile methyl siloxanes (cyclomethicone) and linear polydimethylsiloxanes (dimethicone) have been important ingredients in cosmetic and toiletry products for over 40 years. These two classes of siloxanes represent a very significant portion of the silicones used in personal care products.
Siloxanes are a specific class of silicones which can be divided into volatile methyl siloxanes, because of their vapor pressure and low heat of vaporization, and linear polydimethylsiloxanes. Cyclomethicone and Dimethicone International Cosmetic Ingredient Dictionary and Handbook designations for preferred silicone based component, e.g. siloxanes.
These siloxane materials typically have good functional properties (such as spreadability, slip, and substantivity). They also have pleasant aesthetic properties (they are smooth, silky, non-oily, non-greasy, and non-tacky). Being water insoluble, siloxanes are not compatible with honey and therefore cannot be simply combined with honey to eliminate tackiness.
Of particular interest in the compositions of the present invention are where the silicone based component is a dimethicone, dimethiconol, cyclomethicone tetramer, and cyclomethicone pentamer, and mixtures thereof.
A desirable component for use herein is a glycol. Preferably, the glycol is an aliphatic based glycol. The preferred glycols are propylene glycol and ethylene glycol. The most preferred glycol is propylene glycol. The glycol adds humectant properties to the compositions of the present invention. A convenient source of the glycol is in the Lubrajel CG product
Amounts of the Components
The components of the present invention, are with the exception of water, determined on a solids basis unless otherwise indicated.
The weight ratio of the polyglyceryl-methacrylate to the silicone based component is typically about 75:1 to about 3:1. Preferably, the weight ratio of the polyglycerylmethacrylate to the silicone based component is about 40:1 to about 10:1, and most preferably about 35:1to 12:1.
The weight ratio of the polyglycerylmethacrylate to the polysaccharide in the liquid polysaccharide component is typically about 8:1 to about 1:2. Often, it is convenient to have weight ratio of the polyglycerylmethacrylate to the polysaccharide in the liquid polysaccharide component about 5:1 to about 1:1.
The weight ratio of the polyglycerylmethacrylate to the glycol component is typically about 10:1 to about 1:5. Preferably, the weight ratio of the polyglycerylmethacrylate to the glycol component is about 15:2 to 1:4.
The compositions of the present invention typically contain about 40 to about 90% by weight water. Preferably, the compositions of the present invention contain about 50% to about 80% by weight water.
Additional Components
In addition to the previously mentioned components, the products of the present invention may also comprise further ingredients such as, for example, perfume oils, coloring agents, and preservatives, a carrier or diluent material, and the like.
Product Usage
The products of the present invention may be formulated into lotions, shampoos, hair conditioners, sunscreens, insect repellants and the like. The level of usage in the finished compositions for consumer use is typically to apply the product at 0.1 grams to 50 grams per liter of liquid product applied or directly upon the skin or hair at 0.1 gram to 1 gram per 250 grams of hair or a similar amount to 100 square centimeters of skin surface.
EXAMPLE I
Weight %
Lubrajel CG
69.40
Natural Honey
30.00
Paragon III (preservative)
0.60
100.00
EXAMPLE II
A
B
C
Weight %
Lubrajel CG
69.40
69.40
69.40
Honey
26.00
29.00
28.00
Dow 344 (cyclomethicone)
4.00
0.00
0.00
Dow 200 (dimethicone)
0.00
1.00
0.00
Dow 1401 (cyclomethicone and dimeth-
0.00
0.00
2.00
iconol)
Paragon III (preservative)
0.60
0.60
0.60
100.00
100.00
100.00
The products of the above examples are substantially homogeneous viscous honey-like products with excellent skin feel and no undesirable tackiness after drying. The products may be used as a base for the creation of skin care and hair care products which feature honey ingredient chemistry with enhanced moisturizing potential. The products of the above examples exhibit the functional benefits of enhanced spreadability, slip, and substantivity. | This invention deals with the delivery of liquid polysaccharides to a cosmetic and toiletry products. A unique formulation is prepared which permits the incorporation of honey into such cosmetic and toiletry products. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Korean Patent Application 10-2014-0144103 filed Oct. 23, 2014, the disclosure of which is hereby incorporated in its entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a biomass-derived lubricant base oil and a method for preparing the same. More specifically, the present invention relates to a lubricant base oil containing an aromatic ester lubricant and a method for preparing the same.
BACKGROUND OF THE INVENTION
[0003] Conventionally, the preparation of mineral oil-derived lubricant base oils required drilling of crude oil which is buried underground. From a global environmental point of view, to prepare mineral oil-derived lubricant base oils in such a manner is to add carbon buried underground to the surface circulation system of the earth. Used mineral oil-derived lubricant base oils may be removed by burning or discarded as liquid. During the course of burning, CO 2 is added to the surface circulation system which would otherwise not have been. When discarded as liquid, since mineral oil-derived lubricant base oils possess a very low biodegradability of about 10 to about 30% (based on the CEC analysis method), more serious problems are posed.
[0004] The remainder (i.e. the portion not biodegraded) of the mineral oil-derived lubricant base oils may be absorbed into the ecosystem in the surface circulation system to cause a variety of problems. In addition, from a macroscopic point of view, the problem of serious environmental pollutants, such as sulfur (S), nitrogen (N), heavy metals, etc. present in the crude oil drilled to produce mineral oil-derived lubricant base oils, being included in the surface circulation system and causing troubles cannot be ignored.
[0005] In contrast, the problem of adding carbon in the form of CO 2 to the surface circulation system does not occur in the case of biomass-derived lubricant base oils, because biomass comes from animals or plants which are already present in the surface circulation system, which is to say that carbon already being circulated in the surface circulation system is utilized in this case.
[0006] Since the biomass-derived lubricant base oils inherently have a biodegradability of at least about 70% or more and exhibit a biodegradability of nearly 100%, there is little negative impact posed on the ecosystem from burning or discharging into the nature the biomass fat-derived lubricant base oils which are discarded after use. Of course, toxic substances such as S, N, heavy metals, aromatics, etc. are not present throughout the preparation process.
[0007] Therefore, in order to overcome the above-described problems which the mineral oil-derived lubricant base oils have, preparation technology for a biomass-derived lubricant base oil has been proposed as a way to make an ecofriendly lubricating oil which has high biodegradability and is free of toxic substances (S, N, aromatics, heavy metals).
[0008] In addition, a lubricating oil is a physical mixture of about 80% of a base oil and about 20% of additives. As the substance which most prominently determines lubrication properties—such as viscosity, a viscosity index, a low-temperature fluidity, etc.—of a lubricating oil, a base oil has a hydrocarbon chain structure and can determine major lubrication properties by its structural regularity, molecular weight, etc. However, a lubricating oil may require alterations in the lubrication properties by small extents depending on the application, and, when the lubricating oil does not meet certain standards of lubrication properties, additives may be used to supplement any insufficient lubrication properties. Examples of such additives include a detergent, a dispersant, an antioxidant, a corrosion inhibitor, a viscosity index improver, a pour point depressant, etc. However, most of such additives include aromatic substances, etc. and thus have problems of being poorly miscible with base oils each of which makes up about 80% of a lubricating oil.
[0009] An alkyl naphthalene is introduced to the conventional lubricant base oil for improving a low-temperature fluidity and facilitating a mixing of the lubricant base oil with additives. However, alkyl naphthalenes are substances prepared as a result of bonding between alkyl groups and aromatic compounds and thus have problems of having a low biodegradability.
[0010] Therefore, the development of a lubricant base oil—which is highly biodegradable and also able to inhibit the production of additional CO 2 greenhouse gas and thus is ecofriendly, while also retaining the merits as a dispersant and advantages of an improved low-temperature fluidity, all of which the conventional lubricant base oils have—is immediately required.
SUMMARY OF THE INVENTION
[0011] It is an aspect of the present invention to provide a lubricant base oil that is highly mixable with additives, has an excellent fluidity and is ecofriendly due to its high biodegradability; and a method for preparing a lubricant base oil that is ecofriendly because it does not produce toxic substances such as S, N, aromatic compounds, heavy metals, etc., where the method can also enable an easy control of the physical properties of a desired lubricant base oil by selecting a suitable alcohol compound to be introduced for an esterification reaction.
[0012] One aspect of the present invention relates to a lubricant base oil. The above lubricant base oil contains an aromatic ester lubricant represented by the following Chemical Formula 1:
[0000]
[0013] In the above Chemical Formula 1, R represents a C16-C18 alkyl group or alkenyl group, and Ar represents a phenyl group, a phenyl group substituted with a Cl-C4 alkyl or C6-C10 aryl, a naphthyl group, a naphthyl group substituted with a C1-C4 alkyl or C6-C10 aryl, an anthracene group, or an anthracene group substituted with a C1-C4 alkyl or C6-C10 aryl.
[0014] In a specific example, the above aromatic ester lubricant may be represented by the following Chemical Formula 2 or Chemical Formula 3.
[0000]
[0015] In a specific example, the content of an aromatic ester lubricant (represented by the following Chemical Formula 1) in the above lubricant base oil may be about 1 to about 40 wt %.
[0016] In a specific example, the above lubricant base oil may have a pour point of about −40 to about −5° C., viscosity (at about 100° C.) of about 3.5 to about 6.5 cSt, and a cloud point of about −40 to about −5° C.
[0017] Another aspect of the present invention relates to a method for preparing an aromatic ester lubricant. The above method includes a conversion of biomass fat to fatty acids, a separation of C16-C18 saturated fatty acids and unsaturated fatty acids from the above fatty acids, and an esterification of the above separated C 16-C18 saturated fatty acids and unsaturated fatty acids with aromatic alcohol-based compounds, where the prepared aromatic ester lubricant is represented by the following Chemical Formula 1:
[0000]
[0018] In the above Chemical Formula 1, R represents a C16-C18 alkyl group or alkenyl group, and Ar represents a phenyl group, a phenyl group substituted with a C1-C4 alkyl or C6-C10 aryl, a naphthyl group, a naphthyl group substituted with a C1-C4 alkyl or C6-C10 aryl, an anthracene group, or an anthracene group substituted with a C1-C4 alkyl or C6-C10 aryl.
[0019] In a specific example, the above esterification may refer to an esterification reaction between carboxylic groups of the above fatty acids and hydroxyl groups of the above aromatic alcohol-based compound.
[0020] In a specific example, the above aromatic alcohol-based compound may be phenol, phenol substituted with a C1-C4 alkyl or C6-C10 aryl, naphthol, naphthol substituted with a C1-C4 alkyl or C6-C10 aryl, anthracene, or anthracene substituted with a C1-C4 alkyl or C6-C10 aryl.
[0021] In a specific example, the above esterification reaction is carried out in the presence of an acid catalyst or base catalyst at a reaction temperature of about 30 to about 120° C., where the above acid catalyst may be sulfuric acid (H 2 SO 4 ), perchloric acid (HClO 4 ), nitric acid (HNO 3 ), or hydrochloric acid (HCl), all of which have a purity of about 95% or more, and the above base catalyst may be potassium hydroxide (KOH), sodium hydroxide (NaOH), or sodium methoxide (CH 3 ONa), all of which have a purity of about 95% or more.
[0022] In a specific example, the above fatty acids and above acid catalyst may be mixed in a weight ratio of about 1: about 0.01 to about 1: about 20 to be used in an esterification reaction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 schematically illustrates an esterification reaction mechanism in a method for preparing a lubricant base oil according to a specific example of the present invention.
[0024] FIG. 2 is a graph illustrating the analyzed result of an example of separating fatty acids from a palm fatty acid distillate specimen at various room temperatures.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Hereinafter, embodiments of the present invention will be described in more detail.
[0026] Lubricant Base Oil Containing Aromatic Ester Lubricant
[0027] A lubricant(lube) base oil according to a specific example of the present invention may contain an aromatic ester lubricant represented by the following Chemical Formula 1. In the present invention, a lubricant base oil is defined as an aromatic ester lubricant itself or a lubricating oil constituent containing an aromatic ester lubricant.
[0000]
[0028] In the above Chemical Formula 1, R represents a C16-C18 alkyl group or alkenyl group, and Ar represents a phenyl group, a phenyl group substituted with a C1-C4 alkyl or C6-C10 aryl, a naphthyl group, a naphthyl group substituted with a C1-C4 alkyl or C6-C10 aryl, an anthracene group, or an anthracene group substituted with a C1-C4 alkyl or C6-C10 aryl.
[0029] The aromatic ester lubricant represented by the above Chemical Formula 1 is derived from biomass, and it can serve as both a dispersant (which can make the base oil more mixable with additives) and a pour point depressant (which can improve the fluidity by reducing the pour point) in a lubricant base oil.
[0030] As described above, the composition of a lubricant base oil of the present invention may contain an aromatic ester lubricant represented by the above Chemical Formula 1, or it may be prepared by mixing an aromatic ester lubricant represented by the above Chemical Formula 1 in a certain ratio with a conventional lubricant base oil.
[0031] Specifically, the content of an aromatic ester lubricant represented by the above Chemical Formula 1 may be about 1 to about 40 wt % with respect to the total weight of the lubricating oil composition. When the content of the aromatic ester lubricant falls in the above range, the lube base oil can be expected to have properties that meet lubricating oil property standards. When the content is higher than about 40 wt %, the viscosity and viscosity index become insufficiently low, making the lubricant base oil difficult to be used as a lubricating oil, whereas the lubrication properties and mixing properties that are unique to an aromatic ester lubricant cannot be expected with the content of less than about 1 wt %.
[0032] Specifically, the aromatic ester lubricant represented by the above Chemical Formula 1 may be an aromatic ester compound represented by the following Chemical Formula 2 or an aromatic ester compound represented by the following Chemical Formula 3. When R in the Chemical Formula 1 is such an alkyl group, a better oxidation stability can be secured.
[0000]
[0033] The lubricant base oil according to a specific example of the present invention may have a pour point of about −40 to about −5° C., viscosity (at about 100° C.) of about 3.5 to about 6.5 cSt and a cloud point of about −40 to about −5° C. When the properties fall in the above mentioned ranges, the lubricant base oil can be used as a viscosity index improver, pour point depressant or additive that improves mixing between the base oil and additives.
[0034] Method for Preparing Aromatic Ester Lubricant
[0035] The method for preparing an aromatic ester lubricant according to a specific example of the present invention may include a conversion S10 of biomass fat to fatty acids, a separation S20 of C16-C18 saturated fatty acids and unsaturated fatty acids from the above fatty acids, and an esterification S30 of the above separated C16-C18 saturated fatty acids and unsaturated fatty acids with aromatic alcohols.
[0036] During the conversion S10 of biomass fat to a fatty acid, as is generally known, triglycerides can be extracted from biomass by using a strong acid, a strong base, high temperature steam, etc., and the ester bonds of the above triglycerides can be hydrolyzed to be converted to fatty acids.
[0037] The separation S20 of C16-C18 saturated fatty acids and unsaturated fatty acids from the above fatty acids is required because the above biomass-derived fatty acids include a variety of saturated fatty acids and unsaturated fatty acids. For example, palm oil-derived fatty acids may include myristic acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, monoglycerides, and diglycerides. Such various kinds of fatty acids have boiling points different from one another, and thus, the fatty acids of interest can be selectively separated by extraction by fractional distillation.
[0038] Therefore, C16-C18 unsaturated fatty acids may be separated by extraction from biomass-derived fatty acids through fractional distillation.
[0039] The esterification S30 of the separated saturated fatty acids and unsaturated fatty acids with aromatic alcohols converts the molecular structure of the fatty acids into esters through the esterification reaction between carboxylic groups of the separated fatty acids and hydroxyl groups of aromatic alcohol-based compounds.
[0040] When an ester lubricant contains a carboxylic functional group, it may cause corrosion in an engine. Therefore, stabilization of the chemical structure of the carboxylic functional group by forming an ester through an esterification reaction with an alcohol is required.
[0041] FIG. 1 illustrates the reaction mechanism of the aromatic ester lubricant according to a specific example of the present invention. Referring to FIG. 1 , an example in which an aromatic ester compound is prepared by reacting each of phenol and naphthol (both of which are aromatic alcohol-based compounds) with palmitic acid (which is a C16 saturated fatty acid) is provided.
[0042] There is no limitation to the aromatic alcohol-based compound to be used in an esterification reaction, as long as it is an aromatic alcohol-based compound having a hydroxyl group. Examples of such a compound include phenol, phenol substituted with a C1-C4 alkyl or C6-C10 aryl, naphthol, naphthol substituted with a C1-C4 alkyl or C6-C10 aryl, anthracene, anthracene substituted with a C1-C4 alkyl or C6-C10 aryl, and so on.
[0043] However, it may be beneficial to use low-price aromatic substances such as phenol, naphthol, etc. that are less expensive than the final product so that a volume gain effect can be expected through a preparation of esters with the use of such substances.
[0044] The above esterification reaction is carried out in the presence of an acid catalyst or base catalyst at a reaction temperature of about 30 to about 120° C., where the above acid catalyst may be sulfuric acid (H 2 SO 4 ), perchloric acid (HClO 4 ), nitric acid (HNO 3 ), or hydrochloric acid (HCl), all of which have a purity of about 95% or more, and the above base catalyst may be potassium hydroxide (KOH), sodium hydroxide (NaOH), or sodium methoxide (CH 3 ONa), all of which have a purity of about 95% or more, but they are not limited thereto.
[0045] In the above esterification reaction, the fatty acids and acid/base catalyst may be mixed in a weight ratio of about 1: about 0.01 to about 1: about 20, specifically, about 1: about 0.03 to about 1: about 20 for an esterification reaction.
[0046] Hereinafter, the present invention will be described in more detail with reference to examples, but such examples are merely for illustrative purposes and should not be construed as limiting the present invention.
EXAMPLE
[0047] A. Separation of Fatty Acids
[0048] Fatty acids were separated from a 2 kg-palm fatty acid distillate (PFAD) specimen by a TBP cutting device at various reaction temperatures. The analyzed result of the above PFAD specimen is shown in FIG. 2 , and, from the result, it was found that the PFAD specimen had a composition shown in the following Table 1. The PFAD specimen underwent cutting at 300° C., 355° C., 380° C., and each fatty acid was acquired in the amount shown in the following Table 2.
[0000]
TABLE 1
Type of fatty acids
PFAD composition (wt %)
Myristic acid (C14:0)
3
Palmitic acid (C16:0)
43
Oleic acid (C18:1),
38
Linoleic acid (C18:2),
Linolenic acid (C18:3)
Monoglyceride, diglyceride
16
Total
100
[0049] B. Esterification Reaction
[0050] 500 g of the PFAD separated and acquired in the composition shown in the above Table 1, as well as 292 g of 2-naphthol and 42 g of a 99% pure sulfuric acid, was introduced to a 2 L-flask, the reaction temperature was raised to 60° C., then the mixture was stirred at a speed of 200 rpm for 12 hours. Later, the above reactants were added to a 2 L-beaker and then quenched with a mixed solution of KOH/Ethanol/DI-water (38 g/100 cc/900 cc) while being stirred. The pH was measured to confirm that no residual acid was present in the above mixed solution, and then the mixed solution was set aside to wait for the temperature to decrease, added to a separatory funnel and maintained, and then, when the water layer and organic layer were separated from each other, the water layer was selectively removed. The separated organic layer was again added to the fractional distillation equipment (Spaltrohr HMS 300C by Fischer Technology, Inc.) and underwent cutting at 450° C. for a selective removal of unconsumed fatty acids and naphthol. 117 g of separated, unconsumed reactants and 629 g of the aromatic ester lubricant were acquired.
[0051] Lubricating oil properties of the above aromatic ester compound were measured, and the result is shown in the following Table 2.
[0000]
TABLE 2
Viscosity
Viscosity
Cloud
Pour
TAN
(40° C.)
(100° C.)
point
point (PP)
(mgKOH/kg)
48 cSt
7.9 cSt
−36° C.
−37° C.
0.04
[0052] As seen in the Table 2 above, an aromatic ester compound prepared through an example of the present invention was found to have viscosity properties and a cloud point at the levels equivalent to those of conventional dispersants such as an alkyl naphthalene and can effectively lower the pour point. In addition, the result of TAN analysis in accordance with ASTM D664 standards was 0.04 mgKOH/kg, which could be interpreted as indicating that the reactants were mostly converted to esters.
[0053] So far, examples of the present invention have been described, and it should be understood that the present invention is not limited by the above examples but can be prepared in various different forms and implemented in other specific forms by an ordinary person skilled in the art, without changing the technical scope or essential features of the present invention. Therefore, the examples described above should be understood as exemplary and non-limiting in every aspect. | The present invention relates to a lubricant base oil containing an aromatic ester lubricant represented by Chemical Formula 1 and to a method for preparing the aromatic ester lubricant. By containing an aromatic ester lubricant, the lubricant base oil exhibits an excellent dispersibility and fluidity and is ecofriendly due to a high biodegradability. In addition, the method for preparing the aromatic ester lubricant does not generate such toxic substances as S, N, aromatic compounds and heavy metals and enables an easy control of the physical properties of a desired lubricant base oil by selecting a suitable alcohol compound to be introduced for an esterification reaction. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a method for machining the peripheries of out-of-round workpieces and to a lathe for carrying out this method. The invention is especially useful in the machining of out-of-round raw piston rings with gap sections not yet cut out.
Lathe-like apparatus incorporating a copying device have been employed for the peripheral machining of piston rings having out-of-round inner and outer circumferences. In such apparatus, the piston rings are axially clamped together to form a stack and mounted on a driven spindle for simultaneous machining of their inner and outer circumferences. The tools are attached to the ends of pivotal tool holders provided with a radial adjustment that is controllable by a copying cam rotating in synchronism with the work spindle. In particular, an adjustable dual lever system may be used for controlling the tool for out-of-round machining of piston rings, such apparatus having been operated satisfactorily for many years.
A disadvantage of the prior art machining apparatus is that the maximum number of revolutions of the spindle depends upon the out-of-round shape of the piston ring. Specifically, in the area of the piston ring where the gap is cut after machining and where there is a relatively slight curvature, the copying lever system does not provide a reliable, accurate transfer of the out-of-round contour of the workspindle. This occurs because, with an increase in the number of revolutions in synchronism with the copying cam, the copying roller is lifted off the cam or the mass inertia of the copying lever system is insufficient to assure accurate transfer of the out-of-round contour.
Recently, cutting tools have been developed which permit very high cutting speed thereby permitting an increase in the output of the machining apparatus. This increase in the relative cutting speed between the tool and workpiece requires a simultaneous reduction of the cutting depth or advance in order to reduce mechanical and thermal stresses on the workpiece during the cutting process. Accordingly, it is now possible to reduce to a minumum the undesirable internal stresses which occur in the workpiece structure as a result of the machining process.
It is an object of the present invention to provide a method, and a lathe operating according to this method, which provides optimum cutting conditions during machining of the circumferences of out-of-round workpieces such as piston rings.
SUMMARY OF THE INVENTION
In accordance with the present invention, the piston ring during machining is rotated about its longitudinal axis at a variable or irregular angular speed. The amount of irregularity; i.e. the change in the angular speed per revolution of the workpiece, corresponds to the change in the out-of-round contour of the workpiece so as to obtain an increase in the average circumferential speed of the workpiece by reducing the radial acceleration peaks.
This may be explained as follows.
The circumferential speed of the workpiece namely the piston ring is generally higher than in the case of prior art apparatus. At least for machining the gap section of the piston ring, the circumferential speed is reduced only in this circumferential section to a lower range so that the working tool can exactly follow the very great change in the out-of-round contour in this section. After that, the angular speed of the spindle is accelerated to the prior range. It is to be understood that the average speed is higher than is employed in the prior art so that the optimum cutting conditions are almost reached by this speed varying method.
The present method can be used not only for the machining of out-of-round workpieces, such as piston rings and cam discs, but also for out-of-round shaping by means other than cutting, or during the spraying-on of surface coatings.
If a conventional lathe having a work spindle which accommodates the workpiece and at least one axially and/or radially adjustable tool is employed, the drive motor may be a reversible-pole three-phase motor. The number of revolutions of the rotor of such a motor may be changed by utilizing the inertial movement of the drive system of the lathe. The desired operation is obtained by periodically switching the motor to achieve alternating acceleration and braking thereby producing a fluctuation in the angular speed of the motor drive shaft which corresponds approximately to a sinusoidal oscillation.
In order to obtain relatively high irregular workspindle rotations, a d.c. servomotor may be used as the main drive with the motor being electronically controlled in both directions of rotation by a ramp function stored in a computer. The use of an electronically controllable stepping servomotor has the further advantage that the total number of revolutions of the spindle, as well as the change in the angular speed of the spindle per revolution, can be obtained directly without any intermediate gears. Preferably, the servomotor is disposed flush with the spindle and the armature shaft of the servomotor connected directly to the spindle so as to prevent relative rotation between the two members. Thus, masses which must be accelerated with every step of the motor and which are unavoidable when gear or belt drives are employed are not present in the system.
In many conventional lathes, the workspindle is driven by an electric or hydraulic motor via a belt drive. According to a further feature of the present invention, the control element which determines the angular speed of the spindle comprises an out-of-round belt pulley preferably in the form of an eccentric connected to the spindle. The degree of eccentricity of the belt pulley is a measure of the magnitude of the change in the angular speed of the spindle and thus of the circumferential dimensions of the out-of-round workpiece to be machined.
An energy storage device may also be provided in the drive system of a lathe of the above-described type for the partial storage and discharge of kinetic energy per revolution of the spindle. Such an energy storage device preferably includes a spring which can be tensioned by means of a cam plate that rotates together with the spindle. In addition, a pivot lever having a sensing roller is provided to tension a compression, tension or torsion spring. The influence of the irregular rotary movement of the spindle, which has a reactive effect on the drive motor, is reduced by providing a torsion spring connected to the drive shaft of the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a lathe according to the invention which uses a d.c. servomotor as the main drive.
FIG. 2 is a plot of the angular speed of the workpiece in the lathe of FIG. 1 as a function of the angular displacement of the workpiece during one revolution thereof.
FIG. 3 is a plot of the angular speed of the workpiece in a lathe employing a reversible pole three-phase motor drive as a function of the angular displacement of the workpiece during one revolution thereof.
FIG. 4 is a side view of a lathe having an eccentrically rotating belt pulley.
FIGS. 5 and 6 are front and side views of a lathe including an energy storage device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic representation of a lathe for the simultaneous machining of the internal and external peripheral faces of out-of-round piston rings. The lathe includes a spindle stock 1 holding a sprindle 2 rotatably mounted therein and a counter yoke 3 supporting a rotatable socket 4 to which a piston ring stack 5 may be axially clamped. Tools 6 and 7, which are provided for the internal and external machining of the piston ring stack respectively, are connected to a pivotal rocker bar 10 by means of an arm 8 and an axial rod 9 respectively. The rocker bar 10 is mounted on two posts 12, 12' which are fastened to a longitudinal carriage 11. Additional details of the lathe are found in commonly-assigned copending application Ser. No. 924,732 filed July 14th, 1978 and are incorporated by reference herein.
The radial vibratory movements of tools 6 and 7 caused by the out-of-round circumferential contour of the piston ring are transferred to the rocker bar 10 by a copying cam 13 which rotates in synchronism with the spindle 2 via a lever 14 having a sensing roller. The drive for the spindle is a d.c. servomotor 16 whose armature shaft 17 is connected with the spindle 2 by a belt drive 19. The servomotor is controlled by an electronic computer 20 in which a ramp function has been stored.
In another embodiment of the invention, a servomotor 16' and an encoder 16" are mounted flush with the spindle as shown in dashed lines on FIG. 1. The encoder 16" monitors the angular position of the spindle and the direct mounting of servomotor 16' eliminates the additional elements in the belt drive which would have to be accelerated.
FIG. 2 shows a typical relationship between the angular speed ω of the workspindle 2 and the angular position θ of the workpiece for the lathe of FIG. 1.
In another embodiment of the invention, a reversible pole three-phase motor is used as the drive for the spindle instead of the servomotor 16 or 16'. By alternatingly accelerating and braking the masses of the members comprising the drive system by means of the reversible pole three-phase motor, it is possible to produce degrees of irregularity in the angular speed ω of the drive shaft which vary approximately sinusoidally as a function of the angular position θ of the workpiece, as shown in FIG. 3, thereby assuring a sufficient approximation to various out-of-round shapes, particularly those of piston rings.
FIG. 4 illustrates another embodiment of the invention employing a belt drive. A conventional three-phase motor drives a pulley 30 at a constant speed. Pulley 30 is connected to a cam disc 32, which is attached to the spindle of the lathe, by means of the belt 31. In order to produce an irregular rotary movement of the spindle, cam disc 32 is mounted eccentrically, the magnitude of the eccentricity x determining the change in the angular speed per revolution of the workspindle. A spring-tensioned pressure roller 33 is used to keep the belt tension uniform.
The amount of eccentricity x is determined as follows.
In case of machining raw piston rings, the eccentricity x is derived from the lowest and highest diameter of the raw piston ring with out-of-round contour. Thus, the speed of the spindle is changing sinusoidally between a maximum and a minimum, as shown in FIG. 3. The minimum should be reached in the moment before the working tool arrives at the piston ring gap because the greatest radial accelerations of the working tool are to be realized in the circumferential sections just before and behind the gap.
FIGS. 5 and 6 show a drive system for a lathe according to a further embodiment of the invention wherein the uniform rotary movement generated by a main motor 34 is transmitted to a spindle 36 by means of a belt drive 35. A cam disc 37 fastened to the spindle periodically stretches and relaxes a tension spring 40 by means of a sensing roller 39 disposed at the end of a pivot lever 38 to alternately convert kinetic energy into potential spring-tensioning energy. As a result, the angular speed of spindle 36 is reduced when the spring 40 is tensioned and, as soon as the sensing roller 39 passes over the highest point on the cam disc, the then relaxing spring 40 causes the spindle to accelerate. Since the three-phase drive motor 34 runs at a substantially constant speed, a torsion spring 41 is provided on the drive shaft 42 within the cam disc 43 to produce torsion equalization.
By suitable selection of the system parameters (shape of the cam disc, spring constants and lever arrangement) and taking into account the inertial moments of the system, the degree of irregularity in the angular speed of the spindle is determined.
Basically the cam disc could be an eccentrically mounted disc with an angular periphery. For providing optimum cutting conditions during machining, the peripheral contour of the cam disc is to be found experimentally because the whole machine mechanism is individually to be considered.
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 method and apparatus for circumferentially machining an out-of-round workpiece in which the workpiece is rotated about its longitudinal axis at an irregular angular speed. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims benefit under 35 U.S.C. § 119(e) to provisional Application No. 60/468,639, filed May 8, 2003, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention is directed to fiber tow processing and, more particularly to methods and devices for splicing ends of indeterminate length fiber tow prior to stretching, heat-setting, and cutting the tow into staple lengths.
BACKGROUND OF THE INVENTION
In the conventional manufacture of synthetic textile yarns, a molten polymeric material is extruded in the form of multiple continuous filaments which, after quenching to cool the filaments below their glass transition temperature, are gathered and transported longitudinally in an indeterminate length coextensive bundle commonly referred to as a tow. A driven take-up unit disposed downstream of the extruding apparatus delivers the tow at a controlled transport speed to a canning station at which the tow is deposited into an open-top can or similar container for storage and, in some cases, transportation to another site for further processing.
In a typical drawing operation, tows from a plurality of the filled cans are placed in a common creel for delivery and processing in side-by-side parallel warp sheet form through a draw frame to subject the tows simultaneously to a stretching and heat setting operation to orient the molecular structure of each constituent filament in each tow. Following the stretching and heat setting steps, the tow usually is chopped into staple lengths from which yarn can be spun. Prior to spinning, the staple length tows often are subjected to a carding process to restore uniformity to the material that may be lost during chopping.
In a typical operation, the indeterminate length tow is continuously fed from the container to the stretching and heat setting equipment until the container is emptied. The process is then interrupted, while the leading end of a tow from a new container is joined to the trailing end of the tow from the emptied container by manually sewing the tow ends together. This manual splicing process is sometimes referred to as lacing. FIG. 1B illustrates a tow splice form by lacing.
Once the ends of the new tow and expiring tow are joined, stretching and heat setting processes are resumed. In one typical stretching process, the tow is engaged by a first roller rotating at one rate (e.g., 100 rpm), followed by a closely-spaced second roller rotating at a relatively higher rate (e.g., 300 rpm). Such rollers subject the tow splice to forces on the order of 1,200 lb f . The splice needs to be of sufficient strength to keep the tow ends together during the stretching and heat setting processes. Otherwise, the equipment needs to be shut down to resolve the splice failure, resulting in additional downtime.
The present lacing technique for joining indeterminate length tow ends suffers from several drawbacks. For one, the process is labor-intensive and time-consuming, requiring significant downtime. Another drawback is that a relatively large area of overlap is needed to form a splice having sufficient strength to withstand the ensuing stretching and heat setting operations. This large area of overlap leads to a higher occurrence of inferior quality (or unusable) fiber due to the fibers in the area of the splice not being sufficiently stretched and heat-set. Yet another problem with lacing is the occurrence of so-called wraps, which refer to small portions of the unwoven tow becoming entangled in the rollers of the stretching machine. When this occurs, it is necessary to interrupt operation to clear the entangled tow, producing yet more costly downtime. Lacing also can have result in hard (more dense) areas in the stretched and heat-set staple tow product. The equipment used in many types of downstream textile operations can be sensitive to these hard areas, resulting in production irregularities and/or damage to the equipment.
It would be desirable to develop an alternative technique for joining fiber tow ends, especially one that can be completed in less time than is required for present lacing techniques. It would be desirable to produce splices of consistently high quality, so as to reduce the occurrence of splice failure and associated interruption of the stretching and heat setting or other downstream operations. It also would be desirable to reduce the amount of inferior quality fiber produced due to the large area of overlap needed for the splice in present lacing techniques.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a method of joining indeterminate length fiber tows end-to-end is provided. The method comprises providing a first fiber tow and a second fiber tow. A portion of the first tow is placed over the second tow such that the first and second tows overlap each other in the area of their respective ends. The first and second tows are secured, with at least a portion of the overlapping area exposed. The overlapping area of the tows is positioned on a sewing unit having a sewing head displaceable along first and second axes, and a controller for executing a preprogrammed stitching pattern. The sewing unit is actuated to displace the sewing head along the first and second axes so as to form the preprogranmed stitching pattern in the exposed portion of the overlapping area, thereby splicing the first and second tows.
According to another aspect of the present invention, an apparatus for joining indeterminate length fiber tow ends is provided. The apparatus comprises a substrate supporting surface, a sewing unit having a sewing head displaceable along first and second axes, and means for displacing the sewing head along the first and second axes. The overlapping first and second tow end portions are secured, with at least a portion of the overlapping area exposed in the proximity of the sewing head. A controller actuates the sewing head to apply a preprogrammed stitching pattern in the exposed portion of the overlapping area, thereby splicing the first and second tows.
In accordance with an alternative embodiment of the invention, a method and apparatus for joining indeterminate length fiber tow ends is provided. The apparatus comprises a plate assembly displaceable along first and second axes, a sewing unit having a sewing head positioned adjacent to the plate assembly, and means for displacing the plate assembly along the first and second axes. A portion of a first tow is placed over a second tow such that the first and second tows overlap each other in the area of their respective ends. The overlapping first and second tow end portions are secured in the plate assembly, while at least a portion of the overlapping area is exposed. The plate assembly is controllably displaced along the first and second axes as the sewing head is operated so that a preprogrammed stitching pattern is applied in the exposed portion of the overlapping area, thereby splicing the first and second tows.
According to another aspect of the invention, a fiber tow splice comprises a first fiber tow and a second fiber tow, wherein each tow has a width and wherein an end portion of the first tow overlaps an end portion of the second tow to form an overlapping area. A thread is sewn through the overlapping area in a predetermined stitching pattern. The stitching pattern comprises a plurality of generally parallel lines in the width dimension of the tows, and at least one diagonal line traversing at least some of the generally parallel lines.
The present invention provides an efficient and cost-effective alternative to the current techniques of manually sewing indeterminate-length tow ends together. The present invention overcomes many of the drawbacks of current lacing techniques, especially the extended periods of downtime needed for manual sewing as well as the high occurrence of inferior-quality fiber resulting from the large area of overlap needed for lacing. The present invention also reduces the frequency of downtime associate with the occurrence of wraps in the stretching equipment, and reduces the occurrence of hard areas in the fiber that can be deleterious to downstream textile processing.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features, and advantages of the invention will be apparent from the following more detailed description of certain embodiments of the invention and as illustrated in the accompanying drawings in which:
FIGS. 1A and 1B show a side-by-side comparison of a tow splice prepared in accordance with a preferred embodiment of the present invention (FIG. 1 A), and a tow splice prepared using conventional lacing techniques (FIG. 1 B);
FIG. 2 is a front view of an embroidery machine for splicing fiber tows end-to-end in accordance with a preferred embodiment of the invention;
FIG. 3 is a front view of the embroidery machine of FIG. 2 having first and second tows secured by a clamp in preparation for splicing;
FIG. 4 illustrates a splice being applied by the embroidery machine of FIG. 2 in a preprogrammed stitching pattern;
FIG. 5 is a top view of spliced tow ends, with the tow ends still secured in by a clamp, in accordance with a preferred embodiment of the invention;
FIG. 6 is a perspective view of a clamp for securing first and second tow ends in accordance with a preferred embodiment of the invention;
FIG. 7 is a perspective view of the clamp of FIG. 6 in the open position;
FIGS. 8A-8D illustrate an x-y plate and tow holding assembly in accordance with an alternative embodiment of the invention; FIG. 8A is a perspective view; FIG. 8B is a top view; FIG. 8C is a side view; FIG. 8D is an end view;
FIGS. 9A-9D illustrate the detail of the bottom plate for the assembly shown in FIGS. 8A-8D ; FIG. 9A is a top view; FIG. 9B is a perspective view; FIG. 9C is a side view; FIG. 9D is an end view; and
FIG. 10 is a schematic illustration of a preprogrammed stitching pattern for the splice in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
For convenience, the present invention will be described below with reference to processing synthetic fiber tow, such as polyester, nylon-6, nylon-6,6, polypropylene, acrylic fibers, or blends thereof. It should be understood that the present invention is not limited to processing synthetic fibers, or any particular type of fibers. The methods and devices of the present invention can be used for joining any type of loose fibers, including both natural and synthetic fibers.
The thread used for splicing the tow ends can be selected in accordance with such factors as strength and compatibility with the type of fiber present in the tow being spliced. Generally, it is preferred to use the same type of fiber for the thread as is present in the tow being spliced, although the invention is not limited to any particular type of thread or material for forming the splice.
With reference to FIG. 2 , a commercially available embroidery machine 100 can be modified to splice fiber tow ends in accordance with the present invention. An example of a suitable embroidery machine 100 is a Toyota ESP Model 820. The machine 100 includes a supply 45 of thread, a controller 40 , and a sewing head 35 that is displaceable by actuation of an electric motor along the x and y coordinate axes relative to a stationary substrate support surface 25 . The controller 40 contains a microprocessor for actuating the sewing head to apply a preprogrammed stitching pattern. The machine 100 also includes threaded apertures 27 a , 27 b for receiving screws to secure a clamp to the substrate supporting surface 25 , as described more fully below.
The sewing or embroidery device used for forming the splice can be provided, for example, on a cart equipped with caster wheels to enable the device to be easily transported from one location to another. Alternatively, a sewing or embroidery device can be supported by an overhead pulley and track system to enable the device to be stored overhead when not in use, as well as transported from one location within a facility to another as needed.
FIG. 3 illustrates the machine 100 having overlapping ends of a fiber tow 2 secured in a clamp 50 that in turn is secured to the substrate supporting surface 25 . The sewing head 35 is positioned over the overlapping ends of the tow 2 in preparation for sewing. FIG. 4 shows the sewing head 35 in operation, in which a bobbin 35 a sews thread through the overlapping ends of the tow 2 to form the splice.
A stitching pattern can be selected or designed to provide adequate strength characteristics as may be needed for a particular application. FIG. 5 shows a splice formed on overlapping ends of tow 2 , with the tow still secured in the clamp 50 . The preprogrammed pattern 400 used for this splice, shown schematically in FIG. 10 , includes a plurality of closely-spaced parallel lines 105 a traversing the width direction of the tow 2 , and diagonal lines 105 b forming an “X” across the parallel lines 105 a . When splicing nylon-6,6 fiber tow ends using this pattern, it was found that the splice was sufficiently strong to consistently survive the ensuing stretching and heat setting operations.
The stitching pattern 400 should provide the strength characteristics needed for the splice in a relatively small area. Preferably, the depth d of the overall pattern 400 is less than about 3 inches, more preferably less than about 2 inches. The spacing between the lines parallel lines 105 a typically is about 1/16″. Preferably each of the parallel lines 105 a and diagonal lines 105 b can be double stitched, triple stitched, etc., to increase the strength of the splice.
FIGS. 1A and 1B show a side-by-side comparison of a splice made in accordance with the invention ( FIG. 1A ) and a splice made in accordance with conventional lacing techniques (FIG. 1 B). FIGS. 1A and 1B illustrate overlapping end portions of nylon-6,6 tow 2 a and 2 b , respectively, each wrapped with plastic matrix films 10 a and 10 b , respectively. As can be seen, the stitching pattern 5 a used in the splice of FIG. 1A is considerably more compact than the manually sewn thread 5 b used in lacing, resulting in a narrower splice. The splice of the invention does not require as much overlap as is required for lacing. It is desirable to shorten the area of overlap to reduce the amount of waste and/or inferior quality fiber produced.
The details of a clamp 50 in accordance with a preferred embodiment of the invention are illustrated in FIGS. 6 and 7 . The clamp includes a bottom plate 58 and a top plate 54 which are joined at one end by hinges 52 a and 52 b . Two screws 51 a and 51 b extend from the bottom plate 58 through apertures 53 a and 53 b in the top plate 54 . Wing nuts (not shown) or the like are tightened onto the screws 51 a and 51 b to force the upper plate 54 into contact with the overlapping tow ends placed on the lower plate 58 , to secure the overlapping tow ends in the clamp 50 in preparation for splicing. Each of the lower plate 58 and the upper plate 54 preferably contains strips 58 a and 54 a , respectively, which have a high coefficient of friction for engaging the tow ends. The lower plate 58 has brackets 55 a and 55 b in which holes or grooves 56 a and 56 b , respectively, are formed. Bolts (not illustrated) are fed through the holes or grooves 56 a and 56 b , and are tightened into the threaded apertures 27 a and 27 b (see FIG. 2 ) to secure the clamp 50 to the substrate supporting surface 25 of the embroidery machine 100 . The clamp has an open center portion 57 to enable the sewing head 35 to form the stitching pattern in the portion of the overlapping area that is exposed in the open portion 57 .
FIG. 7 illustrates the clamp 50 in the open position. The upper plate 54 is rotated away from the lower plate 58 via hinges 52 a and 52 b . The open position permits insertion of the overlapping fiber tow ends into the clamp, as well as removal of the spliced tow ends from the clamp 50 following splicing, as discussed more fully below.
As an alternative to an open-face clamp 50 as shown, the overlapping tow ends can be held by any device capable of holding the tow ends without slippage during splicing. By way of example, the tow ends alternatively can be engaged by a cylinder that forces the tow ends against a stationary surface and holds them in place during splicing.
FIGS. 8A-8D illustrate an x-y table 80 having a plate assembly for supporting and displacing the overlapping tow ends as they are spliced by a stationary sewing machine (not shown) in accordance with an alternative embodiment of the invention. The sewing machine is mounted on a support 85 having recessed portions 85 a into which feet of the sewing machine are placed. The x-y table 80 includes linear bearings 81 a , 81 b , 83 a , and 83 b , and linear gears 82 a , 82 b , 88 a , and 88 b that together permit displacement of a plate assembly along the x and y coordinate axes. The plate assembly includes a lower plate 89 and an upper plate 87 for holding the overlapping tow ends. A moving plate 86 displaces the upper/lower plate combination 87 / 89 along the linear bearings 81 a and 81 b . The support 85 is positioned such that the bobbin of the sewing machine is positioned over cut-out portions 97 of the holding plates 89 and 87 .
The overlapping tow ends are placed onto the lower plate 89 . As shown in FIGS. 9A-9D , the lower plate 89 has raised teeth 90 along two edges that are adjacent to a cut-out portion 97 through which the sewing bobbin sews the overlapping tows. The teeth 90 prevent the tow from slipping while it is engaged in the tow holding assembly. The upper plate 87 is placed over the overlapping tow ends, and pegs in the upper plate (not shown) slip into holes 92 in the lower plate to ensure proper alignment. A step motor (not shown) is used to control positioning of the moving plate 86 and the upper/lower plate combination 87 / 89 along their respective axes. A programmable logic controller is used to synchronize movement of the moving plate 86 , the upper/lower plate combination 87 / 89 , as well as operation of the sewing machine to apply a preprogrammed stitching pattern to the overlapping tows.
During a typical splicing operation when using the embroidery machine and clamp assembly shown in FIGS. 2-7 , an optional matrix material is placed onto the lower plate 58 of the clamp 50 while in the open position (FIG. 7 ). An example of a suitable matrix material is Dissolve-Away® Stabilizer, a water-soluble polymeric film available from Sundrop Textiles Inc. of British Columbia, Canada. Another example of a suitable matrix material is a nonwoven fabric. The matrix material is optional and the desirability of its use depends on such considerations as the type of tow material used. It has been found that nylon-6,6 tows, for example, can be spliced with acceptable uniformity without using a matrix material. An appropriate matrix material, when used, can be suitably selected by persons skilled in the art in accordance with the needs of a particular application and with the aid of no more than routine experimentation.
After a section of matrix material is placed onto the lower plate 58 , the overlapping tow ends are placed over the matrix material, and the matrix material is wrapped around the overlapping portion. The upper plate 54 is closed over the tow material, and wing nuts are tightened onto the screws 51 a and 51 b to secure the tow material in the clamp 50 . The clamp 50 then is secured onto the substrate supporting surface 25 of the embroidery machine 100 by tightening screws through the holes 56 a and 56 b in the mounting brackets 55 a and 55 b on the clamp 50 and into the threaded apertures 27 a and 27 b on the supporting surface 25 . The controller 40 is then activated to apply the preprogrammed stitching pattern to the overlapping portion of the tows.
Once the stitching pattern has been applied to the overlapping portion of the tows, the clamp is removed from the supporting surface 25 and opened to remove the newly spliced tow ends. Excess matrix material and any loose fiber material can be cut away and discarded. The stretching and heat setting, or other subsequent processing can then be resumed.
It will be understood that while the invention has been described in conjunction with specific embodiments thereof, the foregoing description and examples are intended to illustrate, but not limit the scope of the invention. Other aspects, advantages and modifications will be apparent to those skilled in the art to which the invention pertains, and these aspects and modifications are within the scope of the invention and described and claimed herein. | Indeterminate length fiber tows ends are joined by overlapping end portions of the first and second fiber tows. The first and second tows are secured in a clamp with a portion of the overlapping area exposed. The overlapping area of the tows is positioned on a sewing unit having a support and sewing head, at least one of which is displaceable along first and second axes, and a controller for executing a preprogrammed stitching pattern. The controller is actuated to form the preprogrammed stitching pattern in the exposed portion of the overlapping area, thereby splicing the first and second fiber tows. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of portable computers systems. Specifically, the present invention discloses a systems for synchronizing a portable computer system with a desktop computer system.
BACKGROUND OF THE INVENTION
[0002] Personal computer systems have become common tools in modern society. To organize their lives, many personal computer users use Personal Information Management (PIM) applications such as an address book, a daily organizer, and a To-Do list applications on their personal computers. Although such Personal Information Management applications have proven useful, their utility is limited by the fact that the person must be sitting at their personal computer system to access the information.
[0003] To remedy this limitation, many palmtop computer organizers have been introduced. A palmtop computer organizer is a computer that is small enough to be held in the hand of a user and runs Personal Information Management (PIM) applications such as an address book, a daily organizer, and electronic notepads. Examples of palmtop computer organizers include the Sharp® Zaurus, the Apple® Newton®, and the Tandy® Zoomer™.
[0004] However, the palmtop organizers also suffer from a number of limitations. Entering information into a palmtop organizer is usually performed by typing on a keyboard that is too small for normal typing or writing onto a digitizer with a stylus and relying on handwriting recognition software. Backing up the information on a palmtop organizer is often difficult and time consuming task requiring special cables and software. Printing the information stored within a palmtop organizer system is difficult since special printer cables are must be connected to connect the palmtop organizer to a printer.
SUMMARY AND OBJECTS OF THE INVENTION
[0005] It is therefore an object of the present invention to provide a easy to use palmtop computer system that is well integrated with a personal computer system. By tightly integrating the palmtop computer system with a personal computer system, an already existing computer infrastructure can easily be used by the palmtop computer system. To integrate to the computer system, the present invention teaches synchronization of information on the palmtop computer system and the personal computer system.
[0006] To integrate the palmtop computer system with a personal computer system in a user friendly manner, the palmtop computer system must be able to handle many different synchronization environments. The palmtop computer system should handle the different synchronization environments in a manner that requires very little user interaction. Thus, the palmtop computer system and the personal computer system must automatically recognized the synchronization environment and perform the synchronization.
[0007] Different synchronization environments include: synchronizing multiple palmtop computer systems with a single personal computer system, synchronizing a single palmtop computer system with multiple personal computer systems, synchronizing a palmtop computer system with a remote personal computer system across a network using a local personal computer system, and remotely synchronizing with a personal computer system across a telephone line. The software architecture of the present invention present invention recognizes each of these different synchronization environments and performs the synchronization of information appropriately.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The objects, features, and advantages of the present invention will be apparent from the following detailed description of the preferred embodiment of the invention with references to the following drawings.
[0009] [0009]FIG. 1 illustrates a two portable computer systems and two personal computer systems equipped with cradles for synchronizing with the portable computer systems.
[0010] [0010]FIG. 2 illustrates a flow diagram that describes how a portable computer system acquires the identification information required to properly perform synchronizations in various environments.
[0011] [0011]FIG. 3 illustrates a flow diagram that describes how to obtain an address for a preferred synchronization personal computer system.
[0012] [0012]FIG. 4 illustrates a block diagram that depicts the software architecture for synchronizing a portable computer through a first personal computer to a second personal computer using a network.
[0013] [0013]FIGS. 5 a, 5 b, and 5 c illustrate a flow diagram describes the beginning of the synchronization between a portable computer system and a personal computer system.
[0014] [0014]FIGS. 6 a illustrates a block diagram that depicts the software architecture for synchronizing a portable computer with a personal computer using two modems and the Public Switched Telephone Network (PSTN).
[0015] [0015]FIG. 6 b illustrates a block diagram that depicts the software architecture for synchronizing a portable computer with a personal computer using a PPP connection between the portable computer system and a network coupled to the personal computer.
[0016] [0016]FIG. 7 illustrates a block diagram that depicts the software architecture for synchronizing a portable computer with a personal computer using a PPP connection between the portable computer system and an Internet Service Provider (ISP).
DETAILED DESCRIPTION
[0017] Methods and apparatus for implementing a palmtop computer system that is well integrated with a personal computer system is disclosed. In the following description, for purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the present invention. In other instances, well-known circuits and devices are shown in block diagram form to avoid obscuring the present invention.
Basic Synchronization
[0018] [0018]FIG. 1 illustrates a portable computer system 130 . The portable computer system 130 may execute a number of different computer programs. However, the most common applications on the portable computer system 130 will consist of a suite of Personal Information Management (PIM) applications such as an addressbook, a daily organizer, a To-Do list, and a memo pad. Most people that use a portable computer system 130 , also have a personal computer system that has the same applications. It would therefore be desirable to synchronize information between the portable computer system 130 and the personal computer system.
[0019] Also illustrated in FIG. 1 is a desktop personal computer system 110 . Coupled to the serial port 113 of the desktop personal computer system 110 is a cradle 120 . The cradle is used to provide a serial communication link between the portable computer system 130 and the personal computer system 110 . Specifically, the serial communication lines from the serial port 113 are extended and terminate at a serial connector 127 on the cradle 120 . A matching serial connector (not shown) on the portable computer system 130 connects the portable computer system 130 to the personal computer system 110 .
[0020] To synchronize the information between the portable computer system 130 and the personal computer system 110 , a user drops the portable computer system 130 into the cradle 120 and presses a synchronization button 125 . The synchronization button 125 causes a synchronization program on the portable computer system 130 to execute. The synchronization program on the portable computer system 130 wakes up a peer synchronization program on the personal computer system 110 . The synchronization program on the portable computer system 130 and the peer synchronization program on the personal computer system 110 perform the necessary operations to synchronize information stored on the two computer systems. The architecture of the synchronization process is described in the U.S. patent application entitled “Extendible Method and Apparatus for Synchronizing Multiple Files On Two Different Computer Systems” with Ser. No. 08/542,055, filed on Oct. 13, 1995.
[0021] To efficiently synchronize the information between the two computer systems, each system maintains a set of status flags for each of the data records. The status flags on each data record identify if the record is new, modified, or deleted. Thus, when a record on the portable computer system 130 or the personal computer system 110 is created, modified, or deleted, the status flags for that record are set to new, modified, or deleted respectively. The status flags on the data records greatly simplify the synchronization process since only the new, modified, or deleted records on each computer system need to be shared with the other computer system. After each synchronization, all the data record status flags are cleared since the two systems have identical databases after the synchronization point.
Synchronization of a Second Portable Computer System
[0022] As described in the previous section, a personal computer system can easily be equipped with a cradle 120 that allows a portable computer system 130 to synchronize with the personal computer system 110 . In this manner, the information on the portable computer system 130 can be backed-up on the personal computer system 110 .
[0023] Each personal computer system usually has ample resources for backing-up several portable computer systems. To back-up another portable computer system, such as portable computer 140 , the second portable computer system 140 can be placed into the same cradle 120 . When the synchronization button is pushed, the synchronization process begins.
[0024] In order to properly back-up the second portable computer system 140 , the personal computer system 110 needs to recognize that the second portable computer system 140 is different from the first portable computer system 130 such that the data from the first portable computer system 130 is not destroyed. To accomplish this goal, each portable computer system is assigned a name. Typically, the name of the portable computer system will be the same name as the user of the portable computer system. The name of the portable computer system is assigned when the portable computer system is first synchronized.
[0025] Then, when the second portable computer 140 system is inserted into the cradle and synchronized, the personal computer system 110 will recognize that a different portable computer system is being synchronize such that a different database will be used. The first time the second portable computer system 140 is synchronized, the personal computer will ask the user if a new account should be created on the personal computer system 110 for storing information from the second portable computer 140 . Thus, a second portable computer can be synchronized on a single personal computer.
Synchronization with a Second Desktop Computer System
[0026] The user of a portable computer system may work with more than one personal computer system. For example, many white collar workers that use a personal computer system at an office often have a second personal computer system at home. The second personal computer system allows the worker to work at night, work on weekends, or telecommute by working at home. It would be desirable to allow such a user to synchronize with both the personal computer at the office and the second personal computer system at home.
[0027] Referring to FIG. 1, a second personal computer system 150 with a second cradle 160 is illustrated. If the portable computer system 130 is placed into the second cradle 160 and the synchronization button 165 is pressed, then the portable computer system 130 will attempt to synchronize with the second personal computer system 150 .
[0028] As described in a previous section, the data records on the portable computer system 130 each have flags that specified if the record is new, modified, or deleted since the last synchronization. However, these flags are only relevant to the particular personal computer system that the portable computer system 130 last synchronized with. If the portable computer system 130 has been synchronized with a first personal computer system 110 and then the user later attempts to synchronize the portable computer system 130 with the second personal computer system 150 , then the status flags on the data records will only relate to the first personal computer system 110 .
[0029] Thus, an interesting problem is created when a portable computer system is synchronized with a first personal computer system, used, and then later synchronized with a second personal computer system. To handle the problem, the synchronization program on each personal computer system stores a copy of the reconciled database after each synchronization. The stored database copy is not modified. Then, when a synchronization must be performed wherein the new, modified, deleted record flags are not available, then the entire contents of the portable computer database is read and compared with the stored database. This comparison will yield a set of records that have been created (new), modified, or deleted since the last synchronization. These new, modified, and delete records can then be used to synchronize with the personal computer's current database. A detailed description of this technique can be found in the U.S. patent application entitled “Method and Apparatus for Synchronizing Information on Two Different Computer Systems” with Ser. No. 08/544,927, filed on Oct. 18, 1995. In this document, a synchronization that requires the copy of the database from the previous synchronization is known as a “slow sync.”
[0030] Before the problem of multiple synchronization hosts for a single portable computer can be solved, the problem first must be detected. To detect the problem of synchronizing with multiple personal computers, the portable computer creates a unique synchronization token after each synchronization. The synchronization token is stored by both the portable computer system and the personal computer system. Later, when a synchronization is attempted, the two systems compare synchronization tokens. If the synchronization tokens do not match, then the portable computer system's last synchronization was with a different personal computer system. In such situations, the reconciled database from the previous synchronization with this computer is fetched to perform the current synchronization.
Synchronization Across a Network
[0031] Personal computer systems are often coupled together into computer networks. When personal computer systems are coupled together into a network, each computer system can its share resources with the other computer systems coupled to the network. Similarly, each computer system can access the shared resources available from the other computer systems coupled to the network.
[0032] When a personal computer that is used to synchronize portable computers is coupled to a network, that network infrastructure can be used to route a synchronization to that “preferred” personal computer. For example, a user of a portable computer system will usually have a personal computer system that is “his” personal computer system. The user will store his personal data such his address lists, his personal calendar, and his To-Do list on his personal computer. New changes to the address list, calendar, and To-Do list will be made to his personal computer. It would therefore be desirable to always synchronize with his personal computer (a “preferred” computer).
[0033] Often, the user of a portable computer system will not be near his personal computer system. But if the user is near a personal computer is coupled to his personal computer through a network, the user can synchronize with his personal computer using the network as a communication medium. To perform this synchronization across the network, the portable computer system must store an identifier that can be used to uniquely address the “preferred” personal computer across the network.
[0034] An example can be provided by referring again to FIG. 1. In FIG. 1, two personal computers 110 and 150 are illustrated. The two personal computers 110 and 150 are coupled together using a computer network 180 . In one embodiment, the computer network 180 uses the TCP/IP suite of protocols. Personal computer 150 will be designated as the user's own personal computer (the “preferred” computer). If the user of portable computer system 130 is near personal computer 110 and wishes to synchronize with his personal computer system 150 , the user simply drops his portable computer system into the cradle 120 of the nearby personal computer 110 and presses the synchronization button 125 . The synchronization process then commences.
[0035] Using the identifier that uniquely addresses the “preferred” computer, the synchronization software in personal computer 110 attempts to reach the preferred computer across the network 180 . If the synchronization software in personal computer 110 can reach the preferred personal computer 150 through the network 180 , then the synchronization software in personal computer 110 simply acts as a pass-through and allows the synchronization software in personal computer 150 to perform the synchronization. This type of synchronization is referred to as a “net synchronization.” If personal computer 110 can not reach the preferred personal computer 150 through the network 180 , then the user may still synchronize with the local personal computer 110 .
Obtaining Synchronization Information
[0036] As described in the previous sections the present invention uses three pieces of identification information in order to synchronize properly: a portable computer user name; a net address of the personal computer; and a unique synchronization token. These three pieces of information are initialized when the portable computer system is first synchronized. The user name for the portable computer will remain static unless the user specifically requests a change. The net address of the personal computer may change due to a request by the user or an automatic update by the synchronization software. A new unique synchronization token is created every time the portable computer system is synchronized with a personal computer system.
[0037] [0037]FIG. 2 illustrates a flow diagram of an initialization the occurs during the first synchronization process of a portable computer system. The initialization occurs when the portable computer system is brand new and has never been used or if all the information in the portable computer has been lost due to malfunction or complete battery discharge.
[0038] Referring to FIG. 2 the flow diagram starts where the Hot Sync Manager on the personal computer system is monitoring the serial port. (As described in previous sections, the synchronization may be performed with other communication means, but in most cases the first synchronization will be across a serial line.) Then, at step 215 , the portable computer requests a synchronization. At step 220 , the Hot Sync manager on the personal computer responds to the synchronization request by sending a request for the identification information on the portable computer system. At step 230 , the portable computer system sends empty identification fields back to the Hot Sync Manager program on the personal computer since the portable computer system is being used for the first time or has lost all of its information.
[0039] Since the portable computer system has not sent any identification information the Hot Sync Manager, the portable computer system is indicating that it is brand new or it has lost its information because of failure. Thus, the Hot Sync Manager on the personal computer system first determines if there is any portable computer system back-up information on the personal computer at step 235 . If back-up information for a portable computer system exists on the personal computer, then at step 240 the Hot Sync Manager asks the user if he wishes to restore the portable computer system using the back-up information stored on the personal computer system. If the user requests to restore the portable computer from the back-up information, the Hot Sync Manager proceeds to step 250 where the portable computer system is restored using the back-up copy of information. Otherwise the system proceeds to step 260 where the process of initializing a new portable computer system begins.
[0040] The first step in initializing a portable computer is to request a name for the portable computer system as stated in step 260 . In one embodiment, the portable computer system simply asks for the name of the intended user. The user name is assigned to the portable computer system such that the portable computer system can be identified during future synchronizations.
[0041] Next, at step 265 , the Hot Sync Manager program attempts to obtain a network address for the personal computer system in order to have a “preferred” personal computer system. The Hot Sync Manager program attempts to obtain an IP address, a host name, and a SubNet Mask that will be used to locate the preferred personal computer system during future synchronization operations across a network. The user name and preferred personal computer network address are stored portable computer system at step 270 . Finally a unique synchronization token for this synchronization session is given to the portable computer system at step 275 . The unique synchronization token will be used next time the portable is synchronized to determine if it is being synchronized on the same computer system that it was last synchronized with.
[0042] [0042]FIG. 3 illustrates how the Hot Sync Manager Program obtains the network address information for the preferred personal computer. First at step 310 the Hot Sync Manager Program determines if the personal computer has TCP/IP services available. If the personal computer does not have TCP/IP protocol services then the Hot Sync Manager Program simply moves to the next step of the synchronization initialization. In an alternate embodiment, the Hot Sync program retrieves a host name for the personal computer name from a Windows registry. The host name from the registry is then later used to obtain the preferred personal computer address for synchronization operations across a network.
[0043] If the personal computer is running TCP/IP protocol, then the Hot Sync Manager proceeds to step 320 where the Hot Sync Manager obtains a host name. The host name may later be used with a Domain name service (DNS) in order to obtain an IP address for the preferred personal computer. After obtaining a host name then the Hot Sync Manager proceeds to step 330 where the Hot Sync Manager determines if the personal computer has been assigned a Internet Protocol (IP) address. If the personal computer has been assigned a IF address then that IP address is stored for future use. Finally, the Hot Sync Manager proceeds to step 340 and attempts to obtain a SubNet Mask.
The Synchronization Process
[0044] Once a portable computer system has been initialized with the proper information, the portable computer system can be synchronized with a main desktop personal computer system in a number of different ways. This section will describe how the portable computer systems synchronizes with the personal computer system with reference to the block diagram in FIG. 4 and the flow diagram in FIG. 5.
[0045] [0045]FIG. 4 illustrates a block diagram of a portable computer system coupled to a personal computer through a serial line for synchronization. The personal computer 420 is also connected to a local area network 450 . Other personal computers such as preferred personal computer 460 are also coupled to the network. The portable computer 410 can synchronize either with the local personal computer 420 or the preferred personal computer 460 across the network.
[0046] [0046]FIG. 5 illustrates a flow diagram that describes on embodiment of the synchronization process in detail. Specifically, FIG. 5 describes most of the steps performed by one embodiment of the Hot Sync Manager program 421 to determine the synchronization environment. Initially the portable computer systems sends a synchronization request at step 505 . In the case where the portable computer 410 is synchronizing through a cradle as illustrated in FIG. 4, the synchronization request is carried across the serial line to the local personal computer 420 . The personal computer 420 recognizes the synchronization request packet and responds by sending a request for additional information from the portable computer system 410 at step 507 .
[0047] In response to the request for additional information, the portable computer 410 sends the three items of identification information as previously described. Specifically, the portable computer system 410 sends the personal computer system 420 the portable system's name, a network address of the preferred personal computer, and the synchronization token received during the previous synchronization at step 509 . At step 510 the synchronization program first checks the last synchronization token to determine if this is the same personal computer that the portable computer last synchronized with. If this is synchronization program first checks the last synchronization token to determine if this is the same personal computer that the portable computer last synchronized with, then the Hot Sync Program immediately performs a fast synchronization at step 515 .
[0048] If this is not the personal computer that the portable computer most recently synchronized with then the synchronization manager program proceeds to step 525 where it determines if network address information is available for both the personal computer 420 on which the Hot Sync Program is running and the “preferred” personal computer requested by the portable computer system.
[0049] If network address information is not available for both the current personal computer and the desired personal computer, then the Hot Sync Manager proceeds to step 527 where it may attempt to do some type of local synchronization. At step 527 , the Hot Sync manager determines if an account for this portable computer exists on this personal computer. If an account exists on this personal computer for the portable then the Hot Sync Manager proceeds to step 530 where a slow synchronization is performed using the last synchronization information available for the portable computer system. If the account for this portable does not exist, the user is asked if a new account should be created at step 580 .
[0050] If at step 525 , the Hot Sync Manager determines that the network address information is available for both the current personal computer and portable's preferred personal computer then the synchronization process proceeds to step 540 . At step 540 the network address of the local personal computer is compared with the network address information of the preferred personal computer. If the two addresses match, then this is the preferred personal computer but portable computer was last synchronized with another personal computer system. In such a situation, the Hot Sync Manager performs a slow synchronization using the information stored from the last synchronization with this personal computer at step 530 .
[0051] If this is not the preferred the personal computer then the Hot Sync Manager proceeds to step 550 to determine if TCP/IP services are available on this personal computer. If TCP/IP services are not available then a synchronization across a network cannot be performed. Thus, the Hot Sync Manager proceeds to step 565 to determine if a local account for this portable exists. If an account exists, a slow synchronization is performed using the information stored from the last synchronization performed with this personal computer. If no local account exists then the user will be asked if a new account should be created.
[0052] However, if this is not the preferred personal computer and TCP/IP services are available, then the Hot Sync Manager will look across the network for the preferred personal computer.at step 555 . If the preferred personal computer can be contacted across the network then the synchronization will be performed with the preferred personal computer across the network. In this situation the local Hot Sync Program 421 merely acts as a pass-through such that all synchronization information passes from the local Hot Sync Program 421 to the remote Hot Sync Program 461 on the preferred personal computer 460 . Thus, the remote Hot Sync Program 461 takes over the Synchronization process and performs a fast sync or slow sync as necessary.
Remote Synchronization
[0053] A person traveling with a portable personal computer system may want to synchronize with a desktop personal computer system while on the road. For example, a traveling executive may wish to receive calendar updates that have been placed into his personal computer by an administrative assistant. One architecture for remotely synchronizing with a desktop personal computer is illustrated in FIG. 6A.
[0054] Referring to FIG. 6A, the portable computer 610 with its Hot Sync Program 615 is coupled to a modem 630 . The Hot Sync Program 615 is configured such that it can initialize the modem 630 and dial another computer system.
[0055] Also illustrated in FIG. 6A is a personal computer system 660 with a Hot Sync Manager Program 661 and a Hot Sync database 663 . To monitor for remote synchronizations the Hot sync Manager can be instructed to listen to a serial line coupled to a modem 669 . If a ring signal is detected by the modem 669 the Hot Sync Manager 661 will answer the call and attempt to begin a synchronization with a remote portable computer system 610 .
[0056] To synchronize remotely, the Hot Sync Program 615 on the portable computer 610 configures the modem 630 and dials the modem 669 coupled to desired personal computer 660 . The modem 669 notices the ringing phone and informs the Hot Sync Manager 661 on the personal computer 660 . The Hot Sync Manager program 661 response by instructing the modem 669 to answer the call. Once the call has been answered, the Hot Sync Manager program 661 listens for a synchronization token. When the Hot Sync Program 615 in the portable computer system 610 notices the call has been answered by another modem, the Hot Sync Program 615 in the portable computer system 610 sends a synchronization request token to the computer that answered. The Hot Sync Manager 661 responds to the synchronization request token by requesting the identification information from the portable computer system 610 . The synchronization progresses as described in the previous sections.
[0057] Although the remote synchronization system illustrated in FIG. 6A is very useful, it suffers from a few drawbacks. The synchronization system illustrated in FIG. 6A requires a dedicated telephone line and a modem for the Hot Sync Manager 661 on the preferred personal computer 660 . Furthermore, the modem 669 is only used to listen for synchronization requests. Additionally, if the user with the portable computer 610 is far away from the personal computer system 660 then a long-distance toll call will be required synchronize with the persona computer system 660 . Therefore an alternate system of remote synchronization is desirable.
[0058] [0058]FIG. 6B illustrates an alternate embodiment of your remote synchronization system. In the alternate embodiment of FIG. 6B, the Hot Sync Program 615 communicates through a TCP/IP stack 617 with a Serial Line Internet Protocol (SLIP) or Point-to-Point Protocol (PPP) client program 619 before communicating with modem 630 . Thus, by using the TCP/IP stack 617 and a SLIP or PPP client program 619 , the Hot Sync Program 615 in FIG. 6B attempts a remote synchronization by performing a net synchronization across a SLIP or PPP link.
[0059] To remotely perform a net synchronization, the Hot Sync Program 615 first establishes a SLIP or PPP link with a server that is coupled to the same network as the preferred personal computer. Thus, the SLIP/PPP software using the modem 630 to dial and connect to a modem 641 on a remote access server 640 . A SLIP/PPP server process 643 on the remote access server 640 will answer the call and establish a SLIP/PPP session. Once the SLIP/PPP session has been created the Hot Sync Program 615 can use the network address of the preferred personal computer to access the Hot Sync Manager Program on the preferred personal computer that is coupled to the TCP/IP Local Area Network 650 . The Hot Sync Manager in the preferred personal computer will be monitoring the TCP/IP packets for a synchronization request across the TCP/IP LAN. If the Hot Sync Manager 661 on the preferred personal computer gets such a synchronization request packet, then the Hot Sync Manager 661 begins a synchronization with the portable computer system.
[0060] The TCP/IP based remote synchronization system can be performed using the global Internet. FIG. 7 illustrates an example of a portable computer system 710 synchronizing with a preferred PC 760 across the global Internet 780 . Specifically the Hot Sync Program 715 in the global computer system establishes a PPP or SLIP connection with an Internet Service Provider (ISP) 740 . The SLIP/PPP session is established between the SLIP/PPP client on the portable computer system 710 and a SLIP/PPP server 743 at the ISP 740 . The SLIP/PPP server at the ISP 740 can communicate across the global Internet to any Internet addressable location. Thus, if the network address of the preferred personal computer 760 is accessible through the global internet 780 then the global computer system 710 can communicate with the preferred personal computer 716 to perform a remote synchronization.
[0061] Many businesses, however, install firewall servers or gateway servers 790 on their Local Area Network as illustrated in FIG. 7. The firewall server acts as a protection mechanism to protect the internal Local Area Network 750 of a company from attacks by unscrupulous Internet users. One method of protecting the internal Local Area Network is to require any communication with the global Internet to pass through a proxy application. In FIG. 7, proxy applications 791 , 792 and 793 are used to bridge various communication protocols. Each proxy application filters the packets associated with its respective protocol before allowing the packets to access the internal Local Area Network 750 . If such firewall system is installed at the corporation of a user who wishes to synchronize a portable computer, then a proxy application for the specific synchronization protocol may be required.
[0062] Although the present invention has been described in terms of specific exemplary embodiments, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | A tightly integrated the palmtop computer system and personal computer system is disclosed. The palmtop computer system and personal computer system synchronize with each other to share information. The synchronization software recognizes different synchronization environments including: synchronizing multiple palmtop computer systems with a single personal computer system, synchronizing a single palmtop computer system with multiple personal computer systems, synchronizing a palmtop computer system with a remote personal computer system across a network using a local personal computer system, and remotely synchronizing with a personal computer system across a telephone line. The synchronization software handles each different synchronization environment appropriately with minimal user interaction. | 8 |
RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/276,182, filed Mar. 15, 2001, and entitled “Miniaturized Reconfigurable DWDM Add/Drop System for Optical Communication Systems.”
This application claims priority from co-pending application Ser. No. 09/999,054 now U.S. Pat. No. 6,510,260, filed Nov. 1, 2001 entitled “NxN Optical Switching Devices Based on Thermal-Optics Induced Total Internal Reflection Effect”, which claims priority from provisional Application Ser. No. 60,259,446, filed Jan. 2, 2001.
This application claims priority from co-pending application Ser. No. 10/097,751, filed Mar. 14, 2002 entitled “Combined Multiplexer and Demultiplexer for Optical Communication Systems”, which claims priority from U.S. Provisional Patent Application Ser. No. 60/276,182, filed Mar. 15, 2001.
This application claims priority from co-pending application Ser. No. 10/098,050, filed Mar. 14, 2002 entitled “Dynamic Variable Optical Attenuator and Variable Optical Tap”, which claims priority from U.S. Provisional Patent Application Ser. No. 60/276,182, filed Mar. 15, 2001.
TECHNICAL FIELD
The present invention is related to optical communications systems for wavelength division demultiplexing, optical signal switching and wavelength division multiplexing and, more particularly, to an optical communication system having a waveguide array for multiplexing and demultiplexing multiple wavelength signals in combination with an array of optical switches which also functions as a variable optical attenuator.
BACKGROUND OF THE INVENTION
The increased demand for data communication and the remarkable growth of the Internet have resulted in increased demand for communication capability within metropolitan areas. There has also been an equally large increase in demand for communication capability between large metropolitan areas. Optical communication systems using a network of fiber optic cables are being developed and installed to meet the increased demand.
The data transmission capacity of fiber optic cables and fiber optic networks has been substantially increased as a result of wavelength division multiplexing (WDM) and dense wavelength division multiplexing (DWDM). Within WDM and DWDM systems, optical signals assigned to different wavelengths are combined (multiplexed) into a multiple wavelength signal for transmission over a single fiber optic cable or other suitable waveguide. A typical DWDM system modulates multiple data streams on to different portions of the light spectrum. For example, one data stream may have an assigned wavelength of 1534 nanometers (nm) and the next data stream may have an assigned wavelength of 1543.8 nm. The required spacing between assigned wavelengths is generally established by International Telecommunications Union (ITU) specifications. These spacings include 0.4 μm and 0.8 μm.
Demultiplexing, the reverse process of multiplexing, typically refers to separation of a multiple wavelength or multi-wavelength signal transmitted by a single fiber optic cable or other suitable waveguide into constituent optical signals for each wavelength. Each optical signal may be further processed to obtain the associated data stream or other information. Both multiplexing and demultiplexing are required for satisfactory operation of WDM and DWDM systems. Multiplexing and demultiplexing of optical signals in conventional DWDM systems are typically performed by two separate relatively expensive and often difficult to manufacture optical devices.
Various types of optical switches and techniques are currently used in optical communication systems. Many currently available optical switches are based upon optoelectric and electrooptic conversion of light signals and electrical signals within the associated optical switch. One type of presently available optical switch includes a matrix of thermooptic switching elements interconnected by waveguides formed on a silica substrate. Switching of light signals is accomplished by the use of thin film heaters to vary the temperature of the switching elements. Electrical circuits are also provided to supply switching current to the heaters. A heat sink may be provided to dissipate heat caused by the switching operations. One example of such switches is shown in U.S. Pat. No. 5,653,008.
Various types of optical signal amplifiers, wavelength division demultiplexers, optical switches, wavelength division multiplexers and techniques are currently used in optical communication systems. Optical signal amplifiers, wavelength division multiplexers and demultiplexers and other components associated with optical communication systems that transmit multiple wavelength light signals typically function best when respective signal levels for the multiple wavelength optical signals are substantially equal with each other. A substantial variation in signal level of multiple wavelength optical signals can result in an undesirable signal to noise ratio and resulting poor performance.
Multiple wavelength optical signals are normally collectively amplified by a light amplifier. The amplification factor of many light amplifiers is dependent upon the wavelength of each optical signal. Therefore, the amplification factors for multiple wavelength optical signals varies depending on the specific wavelength of each signal. The resulting difference between signal levels for multiple wavelength optical signals amplified by a single amplifier is often relatively small. However, when a large number of light amplifiers (ten or more) are used in a fiber optic communication system, the variation in signal levels becomes cumulative and may result in unsatisfactory lowering of associated signal to noise ratios. Therefore, variable optical attenuators are often provided at the input stage and/or output stage of light amplifiers in both large metropolitan communication systems and long distance fiber optic communication systems to adjust signal levels or intensity of multiple wavelength light signals to maintain a desired signal to noise ratio.
Variable optical attenuators are often included in optical communication systems to maintain a desired signal level for each optical signal or wavelength. Examples of variable optical attenuators (VOA) include natural density filters that are often used to suppress the amount of light depending on wavelength characteristics. Other variable optical attenuators include mechanical devices that position a glass substrate so that light signals may be attenuated by varying the position of the glass substrate. Still other variable optical attenuators attenuate light signals by rotating the polarization of each light signal as it passes through a Faraday element.
SUMMARY OF THE INVENTION
In accordance with teachings of the present invention, a system is provided for demultiplexing, switching, attenuating and multiplexing multiple wavelength optical signals using a waveguide array, an array of optical switches and a diffraction grating. An array of waveguides formed in accordance with teachings of the present invention in combination with a lens assembly and a diffraction grating may function simultaneously as both a wavelength division multiplexer and a wavelength division demultiplexer. Optical switches formed in accordance with teachings of the present invention may be used to both switch optical signals and attenuate the respective signal level of optical signals flowing through the switches.
In another aspect, the present invention provides a communication system for multiple wavelength signals including a combined multiplexer/demultiplexer operable to substantially simultaneously multiplex and demultiplex multiple wavelength optical signals. The communication system preferably also includes an array of optical switches operable to.
In a further aspect, the present invention provides a signal processing system having a plurality of waveguide arrays substantially symmetrically disposed relative to an optical axis of the system and an array of optical switches operable to selectively direct optical signal carried by the waveguides. The plurality of waveguides are preferably operable to perform at least one signal processing operation on optical signal reflected from a dispersion apparatus.
Technical benefits of the present invention include providing a communication system or network with substantially reduced insertion loss and substantially reduced manufacturing costs as compared to a conventional communication system or network having a wavelength division demultiplexer, an array of optical switches, a corresponding array of variable optical attenuators, and a wavelength division multiplexer. A single device having an array of waveguides formed in accordance with teachings of the present invention may function simultaneously as a multiple wavelength optical signal multiplexer and demultiplexer that reduces the number of multiplexers and demultiplexers required for a given number of optical signals by one-half.
An array of optical switches formed in accordance with teachings of the present invention may function to switch and attenuate multiple wavelength optical signals as well as eliminate the requirement for separate variable optical attenuators. Therefore, a communication system or network formed in accordance with teachings of the present invention will have approximately one-half the number of components associated with a conventional communication system or network having the same performance characteristics with respect to multiple wavelength optical signals. For example, a conventional communication system or network capable of switching forty channels would normally require a DWDM multiplexer, a DWDM demultiplexer, forty (40) 2×2 optical switches and forty (40) variable optical attenuators. A communication system capable of switching forty (40) optical signals formed in accordance with the teachings of the present invention will require only one (1) bi-directional DWDM multiplexer/demultiplexer and an array of forty (40) optical switches.
The quality of a light signal is determined by the ratio between the signal level and the intensity of noise associated with the light signal. This ratio is commonly referred to as the signal to noise ratio (SNR). Optical switches formed in accordance with teachings of the present invention may be satisfactorily used to adjust the intensity or signal level of multiple wavelength light signals communicated through a fiber optic system to establish the desired signal to noise ratio for optimum performance of amplifiers, bi-directional wavelength division multiplexers/demultiplexers and other components of an optical communication system.
A communication system or network formed in accordance with teachings of the present invention may be satisfactorily used with single mode, multiple mode, or a combination of single mode and multiple mode fibers as input and output fibers and to form fiber or waveguide arrays. A combined multiplexer/demultiplexer formed in accordance with teachings of the present invention may use the same imaging and beam optics, diffraction grating and mechanical packaging to both multiplex and demultiplex multiple wavelength optical signals. Technical benefits of the present invention include substantial savings of cost, space and weight. The present invention is particularly advantageous when more than one multiplexer or demultiplexer is required at the same location in an optical communication system or network. For some applications multiple wavelength optical signals from different channels of a principle fiber line may be separated, dropped, added or cross connected and then recombined into a multiple wavelength optical signal without requiring the use of separate multiple wavelength multiplexers and multiple wavelength demultiplexers.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete and thorough understanding of the present invention and its advantages may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 is a schematic drawing showing an optical communication system formed in accordance with teachings of the present invention including a bi-directional wavelength division multiplexer/demultiplexer and an array of optical switches which also function as variable optical attenuators;
FIG. 2 is a schematic drawing showing a plan view with portions broken away of a 2×2 optical switch satisfactory for use with the optical communication system of FIG. 1 ;
FIG. 3 is a graph showing optical output or signal level versus time measured at the drop port of the optical switch of FIG. 2 for a given current flow through the electrode heater;
FIG. 4 is a graph showing attenuation of an optical signal measured at the drop port associated with the optical switch of FIG. 2 ;
FIG. 5 is a schematic drawing showing a plan view of another embodiment of an optical switch satisfactory for use with the optical communication system of FIG. 1 ;
FIG. 6 is a schematic drawing in section taken along line 6 — 6 of FIG. 5 ;
FIG. 7A is a schematic drawing showing an isometric view of a bi-directional wavelength division multiplexer/demultiplexer satisfactory for use with the optical communication system of FIG. 1 ;
FIG. 7B is a schematic drawing showing an isometric view of an alternate embodiment of the bi-directional wavelength division multiplexer/demultiplexer depicted in FIG. 7A ; and
FIG. 8 is a schematic drawing showing another embodiment of an optical communication system formed in accordance with teachings of the present invention including a bi-directional wavelength division multiplexer/demultiplexer and an array of optical switches which also function as variable optical attenuators.
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention and its advantages are best understood by referring to FIGS. 1 through 8 of the drawings, like numerals being used for like and corresponding parts of the various drawings.
The terms “optical signal or signals” and “light signal or signals” are used in this application to include the full range of all electromagnetic radiation which may be satisfactorily used to communicate information using a waveguide and/or fiber optic cable. A bi-directional wavelength division multiplexer/demultiplexer incorporating teachings of the present invention may be satisfactorily used with such optical signals. An array of optical switches incorporating teachings of the present invention may be satisfactorily used to both switch and attenuate or reduce the intensity or signal level of such optical signals. Signal level or intensity may also be referred to as “optical power.”
The terms “bi-directional wavelength division multiplexer/demultiplexer” and “combined multiplexer/demultiplexer” are used in this application to refer to an optical device that may be satisfactorily used to simultaneously multiplex multiple wavelength optical signals and demultiplex multiple wavelength optical signals. A bi-directional wavelength division multiplexer/demultiplexer formed in accordance with teachings of the present invention may also be used to only demultiplex multiple wavelength optical signals or multiplex multiple wavelength optical signals as desired for a specific communication system.
The term “waveguide ” is used in this application to include the full range of optical devices that may be satisfactorily used to communicate optical signals. A waveguide typically includes a core formed from a first optical material and disposed in a channel formed in a second optical material. A fiber optic cable is one example of a specific type of waveguide. However, waveguides satisfactory for use with the present invention may have various configurations other than fiber optic cables and cores disposed in a channel.
Various features of the present invention will be described with respect to an optical communication system or network such as communication system 20 shown in FIG. 1 and communication system 120 shown in FIG. 8 . An optical communication system or network formed in accordance with teachings of the present invention may be satisfactorily used in long distance fiber optic communication systems (not expressly shown) or large metropolitan area optical communication systems (not expressly shown). Various features of the present invention will be described with respect to a multiple wavelength signal having four spectral components (λ 1 , λ 2 , λ 3 and λ 4 ). However, the present invention may be used with multiple wavelength optical signals having any number of spectral components or wavelengths.
For the embodiment of the present invention shown in FIG. 1 , communication system 20 preferably includes a plurality of signal carriers, such as input fiber optic cable 21 and output fiber optic cable 22 . Wavelength division multiplexing (WDM) techniques may be used to allow signal carriers or fiber optic cables 21 and 22 to carry multiple optical signals at various wavelengths, substantially increasing the efficiency of signal carriers or fiber optic cables 21 and 22 . Dense wavelength division multiplexing (DWDM) techniques have been developed to allow existing fiber optic networks to better satisfy increased demand for communication capabilities.
Various features of the present invention will be described with respect to communicating an optical signal having at least four wavelengths (λ 1 , λ 2 , λ 3 and λ 4 ) Respective amplifiers (not expressly shown) may be coupled with input signal carrier or fiber optic cable 21 and output signal carrier or fiber optic cable 22 . Communication system 20 preferably includes bi-directional wavelength division multiplexer/demultiplexer 40 and at least one array of optical switches 100 . For purposes of illustrating various features of the present invention optical switches 100 have been designated 100 a , 100 b , 100 c and 100 d . A plurality of fiber optic cables and/or waveguides 31 , 32 , 33 and 34 are preferably coupled with bi-directional wavelength division multiplexer/demultiplexer 40 and respective optical switches 100 .
Bi-directional wavelength division multiplexer/demultiplexer 40 may include two or more waveguide arrays or sets of waveguides. For the embodiment of the present invention shown in FIGS. 7A , 7 B and 8 , the first waveguide array has been designated 51 . The second waveguide array has been designated 52 . For purposes of describing various features of the present invention, the portion of fiber optic cables and/or waveguides 31 - 34 used to couple optical switches 100 a , 100 b , 100 c , and 100 d with first waveguide array 51 are designated 31 a , 32 a , 33 a and 34 a . The portion of fiber optic cables and/or waveguides 31 - 34 which couple optical switches 100 a , 100 b , 100 d and 100 c with second waveguide array 52 are designated 31 b , 32 b , 33 b and 34 b . Arrows have been added to show the direction of optical signal travel through fiber optic cables and/or waveguides 31 , 32 , 33 and 34 . See FIGS. 1 and 8 .
Input signal carrier or fiber optic cable 21 preferably provides multiple wavelength signal (λ 1 , λ 2 , λ 3 , λ 4 ) to bi-directional wavelength division multiplexer/demultiplexer 40 . Bi-directional wavelength division multiplexer/demultiplexer 40 is preferably operable to demultiplex the multiple wavelength signal into its individual spectral components. During the demultiplexing process, the optical signal corresponding with λ 1 is preferably directed through fiber optic cable and/or waveguide 31 b to optical switch 100 a . In a similar manner optical signals corresponding with wavelengths λ 2 , λ 3 and λ 4 are preferably directed by fiber optic cables and/or waveguides 32 b , 33 b and 34 b to respective optical switches 100 b , 100 c and 100 d.
As discussed later in more detail, optical switches 100 may direct the respective optical signals (λ 1 , λ 2 , λ 3 or λ 4 ) to respective drop ports (not expressly shown) coupled with fiber optic cables designated 71 , 72 , 73 and 74 or to respective fiber optic cables and/or waveguides 31 a , 32 a , 33 a and 34 a . Fiber optic cables 61 , 62 , 63 and 64 may supply optical signals having respective wavelengths λ 1 , 80 2 , λ 3 and λ 4 to add ports (not expressly shown) at respective optical switches 100 a , 100 b , 100 c and 100 d.
The portions of communication system 20 shown in FIG. 1 and communication system 120 shown in FIG. 8 include respective input and output fiber optic cables, four add ports and four drop ports. However, various communication systems may be formed in accordance with teachings of the present invention using bi-directional wavelength division multiplexer/demultiplexers and multiple arrays of optical switches having any number of input and output channels, add ports and drop ports.
FIG. 2 is a schematic drawing showing a plan view of one example of an optical switch incorporating teachings of the present invention. Optical switches 100 a , 100 b , 100 c and 100 d have substantially the same design as the optical switch depicted in FIG. 2 . For the embodiment shown in FIG. 2 , optical switch 111 preferably includes first waveguide 101 and second waveguide 102 . Each waveguide 101 and 102 also includes respective input ends “a” and output ends “b”. Although various features of the present invention will be described with respect to an optical signal traveling from input end “a” to output end “b” of a waveguide, an optical switching device formed in accordance with teachings of the present invention may be satisfactorily used to switch or redirect optical signals traveling in either direction through the waveguide.
For the embodiments of the present invention represented by communication systems 20 and 120 , input end 101 a of each optical switch 100 a , 100 b , 100 c and 100 d is preferably coupled with respective fiber optic cables and/or waveguides 31 b , 32 b , 33 b and 34 b . Output end 102 a of each optical switch 100 a , 100 b , 100 c and 100 d is preferably coupled with respective fiber optic cables and/or waveguides 31 a , 32 a , 33 a and 34 a . Input end 102 a of each optical switch 100 a , 100 b , 100 c and 100 d is preferably coupled with a respective add port and fiber optic cable 61 , 62 , 63 and 64 . Output end 101 b of each optical switch 100 a , 100 b , 100 c and 100 d is preferably coupled with a respective drop port and fiber optic cables 71 , 72 , 73 and 74 .
For embodiments of the present invention represented by communication systems 20 and 120 , optical signals may travel from input end 101 a through first waveguide 101 to output end 101 b or may be directed by switch 111 to travel through second waveguide 102 to an output port (not expressly shown) coupled with output end 102 b . Except for insertion losses and other minor losses associated with an optical signal traveling through a waveguide, the optical power level of an optical signal entering input end 101 a is approximately equal to the total optical power level exiting from output end 101 b plus output end 102 b . Except for insertion losses and other minor losses associated with transmission of an optical signal through a waveguide, the total optical energy level or power level of optical signals communicated through optical switch 111 remains substantially constant.
An add port (not expressly shown) may be coupled with input end 102 a of second waveguide 102 . Add signals will generally travel from input end 102 a through second waveguide 102 to the output port (not expressly shown) coupled with output end 102 b . A drop port (not expressly shown) may be coupled with output end 101 b of each of first waveguide 101 . Fiber optic cable 71 , 72 , 73 and 74 are preferably coupled with respective drop ports.
Angle α defined by intersection or junction 103 between first waveguide 101 and second waveguide 102 is preferably selected to be in the range of approximately two degrees (2°) and eight degrees (8°). For at least one application, for example using Silicon Oxide (SiO), angle α is preferably equal to approximately three degrees (3°). For some polymers, angle α is preferably equal to approximately six degrees (6°). By forming optical switch 111 with angle α having a value between approximately two degrees (2°) and eight degrees (8°), an optical signal may travel through first waveguide 101 from input end 101 a to output end 101 b without any significant perturbation or reflection at intersection or junction 103 unless the index of refraction at junction 103 is changed in accordance with teachings of the present invention. The index of refraction at junction 103 may be changed by thermooptic, electrooptic, magnetooptic, or acoustooptic effects.
Electrode heater 104 is preferably disposed adjacent to junction or intersection 103 to produce desired thermooptic effects. Electrode heater 104 may be formed from various types of materials including nickel chrome alloys (NiCr) and chromium gold (Cr/Au), and other metal and alloys. Electrode heater 104 may be used to apply a desired amount of heat to junction or intersection 103 to direct or deflect optical signals from first waveguide 101 to second waveguide 102 or from second waveguide 102 to first waveguide 101 . As discussed later in more detail, electrode heater 104 may also be used to attenuate the signal level of optical signals in waveguides 101 and 102 .
When electrical current is supplied to electrode heater 104 , heating will occur in a cladding layer 114 disposed between electrode heater 104 and junction 103 , see FIG. 6 ,to produce a desired thermooptic effect such as attenuation of an optical signal and/or switching of an optical signal. For example, an optical signal corresponding with wavelength λ 1 may be directed to input end 101 a of waveguide 101 . An appropriate amount of electrical current may be supplied to electrode heater 104 to provide a desired amount of heating at intersection or junction 103 to direct at least a portion of the optical signal corresponding with wavelength λ 1 from waveguide 101 to waveguide 102 and output end 101 b . Attenuation of optical signals will be discussed in more detail with respect to the graphs shown in FIGS. 3 and 4 .
The configuration and location of electrode heater 104 allows selected heating of portions of waveguides 101 and 102 to form what may be considered an imaginary mirror disposed along a longitudinal center line of intersection 103 . Heating cladding layer 114 and portions of waveguides 101 and 102 at intersection 103 will permit a change in the refractive index such that total internal refraction may be achieved. In effect, heating caused by electrode heater 104 at or above a selected value will provide an imaginary mirror at intersection 103 that reflects or deflects light signals from waveguide 101 to waveguide 102 . The same total internal refraction or imaginary mirror effect will also cause optical signals traveling through second waveguide 102 to be reflected or deflected into first waveguide 101 .
For the embodiment of the present invention shown in FIG. 2 , current may flow from variable current source 106 through lead 108 to electrode heater 104 and return through electrical lead 110 to ground 112 . The current flow through electrode heater 104 may be varied in accordance with teachings of the present invention to allow switch 100 to function as a variable optical attenuator. Waveguides 101 and 102 , electrode heater 104 , current source 106 , electrical leads 108 and 110 and ground 112 may be formed on a substrate using conventional semiconductor fabrication techniques.
FIG. 3 is a graph showing optical signal level versus time for a given current flow. For one example of an optical switch 111 , optical signal level was measured at output end 101 b of first guide 101 versus time in seconds at a substantially constant current flow through electrode heater 104 . The current supplied to electrode heater 104 was maintained at approximately forty (40) milliamps for thirty six hundred (3600) seconds or sixty (60) minutes.
FIG. 4 is a graph showing output power or signal level in decibels (dB) measured at output end 101 b of waveguide 101 versus electrical current flow through electrode heater 104 . An optical signal with constant power or signal level was supplied to input end 101 b of waveguide 101 while the electric current flow to electrode heater 104 was varied in accordance with teachings of the present invention. As previously noted, the power level or signal level of an optical signal entering input end 101 b of waveguide 101 is generally equal to the combined power level or signal level of optical signals exiting from output end 102 b of waveguide 102 and output end 101 b of waveguide 101 . Therefore, a similar measurement of output power or signal level measured at output end 102 b of waveguide 102 would be approximately the inverse of the graph shown in FIG. 4 .
The graphical information shown in FIG. 4 demonstrates that for an optical switch such as optical switch 111 , increasing current flow through electrode heater 104 may be used to attenuate or decrease the output power or signal level of an optical signal traveling between input end 101 a to output end 101 b of waveguide 100 . In the same manner, the output power or signal level of the portion of the optical signal directed to output end 102 b of waveguide 102 may be selectively increased. For this embodiment of the present invention, the attenuation of an optical signal at output end 101 b or increase in optical signal at output end 102 b is particularly significant between approximately twenty-two (22) milliamps and forty (40) milliamps.
As the current flow through electrode heater 104 is increased from zero to forty (40) milliamps, an increasing portion of an optical signal that enters input end 101 a of waveguide 100 will be directed towards output end 102 b of waveguide 102 . The total sum of the optical signals exiting from output end 101 b and output end 102 b is generally equal to the signal level of the optical signal entering input end 101 a . Therefore, an array of optical switches formed in accordance with teachings of the present invention may be used to control the signal level of each optical signal exiting from respective output end 102 b and directed to respective fiber optic cables and/or waveguides 31 a , 32 a , 33 a and 34 a . By varying the current supplied to respective electrode heaters 104 of optical switches 100 a , 100 b , 100 c and 100 d , the output of each optical signal corresponding with wavelength λ 1 , λ 2 , λ 3 and λ 4 may be adjusted to approximately the same value. Thus, the signal levels of the optical signals returned to bi-directional multiple wavelength multiplexer/demultiplexer 40 are maintained substantially equal with each other.
FIG. 5 is a schematic drawing showing additional details associated with one embodiment of optical switch 111 . Examples of low resistance electrical leads 108 and 110 are shown in more detail. For the embodiment of the present invention as shown in FIG. 5 , electrode heater 104 has a generally rectangular configuration defined in part by a pair of longitudinal edges 104 a and 104 b and a pair of lateral edges 104 c and 104 d . Longitudinal edges 104 a and 104 b may have a length of approximately two hundred fifty micrometers (250 μm). Lateral edges 104 c and 104 d may have a length of approximately ten micrometers (10 μm). The thickness of electrode heater 104 is preferably very small, almost zero, as compared with the thickness of first waveguide 101 and second waveguide 102 .
Also depicted in FIG. 5 is that longitudinal edge 104 b of electrode heater 104 is preferably disposed on a line that corresponds generally with the longitudinal center line of junction or intersection 103 between first waveguide 101 and second waveguide 102 . For some applications, the vertical spacing or distance between electrode heater 104 and the corresponding junction or intersection 103 is approximately five micrometers (5 μm) and preferably within a range of plus or minus 0.5 μm. The lateral offset between longitudinal edge 104 b of electrode heater 104 and the corresponding longitudinal center line of intersection 103 is preferably less than 9.5 μm. When the offset between electrode heater 104 and the respective intersection 103 exceeds these limits, desired heating of intersection or junction 103 and resulting internal reflection of an optical signal traveling therethrough may not occur as desired.
FIG. 6 shows one example of waveguides formed on a substrate using semiconductor fabrication techniques to produce an optical switching device incorporating teachings of the present invention. For the embodiment of the present invention shown in FIG. 6 , substrate 116 may be part of a typical silicon wafer used in semiconductor fabrication. However, an optical switching device may be formed in accordance with teachings of the present invention on a wide variety of substrates and is not limited to use with only conventional silicon substrates.
For the embodiment of the present invention shown in FIG. 6 , optical switch 100 preferably includes layer 118 disposed immediately adjacent to substrate 116 . Layer 118 may be formed from various types of material such as silicon dioxide (SiO 2 ), or other materials such as Teflon AF 240. First waveguide 101 and second waveguide 102 may be formed from various types of material such as a combination of silicon dioxide and germanium oxide (SiO 2 :GeO 2 ) with an index of refraction of approximately 1.4538. For some applications, layer 118 may have a thickness of approximately fifteen micrometers (15 μm) with an index of refraction of approximately 1.445.
Waveguides 101 and 102 are preferably formed on layer 118 and disposed in respective channels 115 and 117 formed in cladding layer 114 . For one embodiment, channels 115 and 117 preferably have a generally rectangular cross section with dimensions in the range of approximately of six or seven micrometers (6 or 7 μm). Layer 114 may sometimes be referred to as “top cladding”. Layer 114 may be formed from Teflon AF 1600 having an index of refraction of approximately 1.31. The thermooptic coefficient of many polymers is generally less than zero. As a result, when the temperature of such polymers is increased, the corresponding index of refraction is reduced. Teflon AF 1600 represents one example of a polymer having the desired thermooptic coefficient.
For other applications first layer 118 may be formed from silicon dioxide having a thickness of approximately 2.4 micrometers (2.4 μm). Second layer or top cladding 114 may be formed from polymeric material such as Ultradel 9021 having an index of refraction of approximately 1.526. Waveguides 101 and 102 may be formed from Ultradel 9120 having an index of refraction of approximately 1.5397.
For still other applications first layer 118 may be formed from Teflon AF 240 having an index of refraction of approximately 1.29. Second layer or top cladding 114 may be formed from Teflon AF 240 having an index of refraction of 1.29. The thickness of first layer 118 may be approximately five micrometers (5 μm). Waveguides 101 and 102 may be formed from Teflon AF 160 having an index of refraction of approximately 1.31.
Waveguides 101 and 102 may be formed from a wide variety of materials including polyimide, Teflon, PFCB, a mixture of silicon dioxide and polymer, ion exchange and polymer and fluorinated polyimide. Layer 114 may be formed from Ultradel polymer U 9120 having a refraction index of 1.5397 and waveguides 101 and 102 of Ultradel U 9020 having a refraction index of 1.526.
FIGS. 7A and 7B are schematic drawings showing portions of combined multiplexer/demultiplexers 140 a and 140 b , respectively, which may be satisfactorily used with communication systems 20 and/or 120 . A combined multiplexer/demultiplexer incorporating teachings of the present invention may also be used with optical sensors and spectroscopy equipment. Optical components associated with combined multiplexer/demultiplexer 140 a or 140 b include fiber optic input cable 121 and fiber optic output cable 122 , see FIGS. 7B and 8 , which are respectively coupled with first waveguide array 51 and second waveguide array 52 . Other optical components of combined multiplexer/demultiplexer 140 include light focusing device 142 and dispersion apparatus or diffraction grating 144 .
Various types of reflective diffraction gratings and transmissive diffraction gratings may be satisfactorily used with a combined multiplexer/demultiplexer formed in accordance with teachings of the present invention. For some applications diffraction grating 144 may be a Littrow assembly or a Litmann Metcalf assembly or any other diffraction grating satisfactory for separating a multiple wavelength optical signal into selected spectral components and combining individual optical signals corresponding with selected spectral components into a multiple wavelength optical signal. Various types of dispersive elements in addition to diffraction gratings may also be used.
As illustrated in FIGS. 7A and 8 , first waveguide array 51 , second waveguide array 52 , light focusing device 142 and diffraction grating 144 are preferably optically aligned with each other along optical axis 146 . First waveguide array 51 and second waveguide array 52 are preferably symmetrically disposed with respect to optical axis 146 . In an alternate embodiment, illustrated in FIG. 7B , substantially symmetric disposition of signal carriers or fiber cables 121 , 122 and waveguide arrays 51 , 52 may be achieved by aligning fiber cables 121 , 122 and waveguide arrays 51 , 52 on opposing sides of optical axis 146 . As a result of aligning first waveguide array 51 and second waveguide array 52 with optical axis 146 as illustrated in FIGS. 7A and 8 or by aligning fiber cables 121 , 122 and waveguide arrays 51 , 52 as illustrated in FIG. 7B , combined multiplexer/demultiplexers 140 a and 140 b may substantially simultaneously demultiplex multiple wavelength optical signals received from fiber optic input cable 121 and multiplex respective optical signals into a multiple wavelength optical signal directed to fiber optic output cable 122 . The present invention allows first waveguide array 51 and second waveguide array 52 to use common optical beam handling components and dispersion components such as light focusing device 142 and diffraction grating 144 . For some applications, light focusing device 142 may include a single bi-convex lens or any other lens assembly operable to collimate diverging light or focus collimated light as desired. For some applications, diffraction grating 144 may have a blazed surface (not expressly shown).
For the embodiment of the present invention shown in FIGS. 7A and 8 , input fiber 121 may be disposed at one end of first waveguide array 51 and output fiber 122 may be disposed at the same end of second waveguide array 52 . Input fiber 121 is preferably located immediately adjacent to and disposed above output fiber 122 . For the embodiment of the present invention shown in FIG. 7A , first waveguide array 51 and second waveguide array 52 may be formed by plurality of fiber optic cables disposed in respective “v” grooves. For other applications, as illustrated in FIGS. 7B and 8 , first waveguide array 51 and second waveguide 52 may be formed using semiconductor fabrication techniques by placing a waveguide core in a respective waveguide channel. See also FIG. 6 . The present invention allows fabricating multiple waveguide arrays, stacked relative to each other, using such semiconductor fabrication techniques.
For the embodiment of the present invention shown in FIGS. 7A and 8 , a portion of input fiber optic cable 121 may be used to provide waveguide 51 a . In a similar manner, a portion of output fiber optic cable 122 may be used to provide waveguide 52 a . In a similar manner, as illustrated in FIG. 8 , portions of fiber optic cables 31 , 32 , 33 and 34 may be used to provide respective waveguides 51 b through 51 e and 52 b through 52 e.
During operation of combined multiplexer/demultiplexer 140 a , input fiber 121 may be used to communicate a multiple wavelength optical signal to input waveguide 51 a . Light focusing device 142 and diffraction grating 144 cooperate with each other to reflect and disperse the multiple wavelength optical signals emitted from input waveguide 51 a into selected spectral components directed to respective waveguides 52 b through 52 e of second waveguide array 52 , preferably employing inverse symmetry. For the embodiment shown in FIGS. 7A and 8 , second waveguide array 52 in combination with light focusing device 142 and diffraction grating 144 function as a demultiplexer.
Combined multiplexer/demultiplexer 140 b of FIG. 7B operates in a similar manner. For example, a signal may be received by light focusing device 142 from input cable 121 . Light focusing choice 142 may then direct the multiple wavelength signal to dispersion apparatus or diffraction grating 144 . At diffraction grating 144 , the optical signal is preferably diffracted into a plurality of selected spectral components and reflected back to light focusing device 142 . Light focusing device 142 then preferably directs the spectral components to one or more waveguides or waveguide arrays. The waveguides or waveguide arrays then preferably perform one or more signal processing operations, e.g., multiplexing, demultiplexing, attenuation, adding, dropping, etc., on the spectral components. In one embodiment, one or more processed signals may be communicated by cable 121 or 122 .
As another operating example, input fiber 121 could be an input from a telecommunications line that contains many different wavelength channels. The signals from the different channels would be reflected and dispersed across the bottom row of receiving fibers in array 52 . The different wavelength signal of each channel would go into a different fiber in array 52 to be separated or demultiplexed. In an opposing manner, the array 51 could be simultaneously used to recombine all the different wavelengths from individual channels, one in each fiber, by the dispersion and reflection from the diffraction grating on to output fiber 122 . The recombined signals would be sent out on output fiber 122 (multiplexed); thus, making a combination multiplexer/demultiplexer in one module.
Respective optical signals from other sources such as optical switches 100 a , 100 b , 100 c and 100 d may be coupled with waveguides 51 b through 51 e of first waveguide array 51 . Light focusing device 142 and diffraction grating 144 preferably cooperate with each other to combine or multiplex respective optical signals from waveguides 51 b through 51 e of first waveguide array 51 into a multiple wavelength optical signal. Light focusing device 142 directs the multiple wavelength optical signal to output waveguide 52 a of second waveguide array 52 again employing inverse symmetry. Signals from sources other than switches 100 may be coupled with waveguides 51 b through 51 e of first waveguide array 51 and multiplexed by dispersion and reflection from diffraction grating 144 into a multiple wavelength optical signal that is directed to output waveguide 52 a of second waveguide array 52 .
By positioning and forming first waveguide array 51 and second waveguide array 52 based on inversion symmetry with respect to optical axis 146 or by providing inversion symmetry between signal carriers 121 , 122 and waveguide arrays 51 , 52 , imaging and reflection from diffraction grating 144 allows substantially simultaneous multiplexing and demultiplexing of multiple wavelength optical signals. The present invention is not limited to only a first waveguide array and a second waveguide array or a first input cable and a second input cable. Multiple multiplexing and demultiplexing functions may be satisfactorily formed by disposing any desired number of waveguide arrays and signal carriers, with appropriate inversion symmetry, relative to a light focusing device, a dispersion device and the associated optical axis.
Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may be suggested to one skilled in the art and it is intended that the present invention encompass such changes and modifications fall within the scope of the appended claims. | A DWDM add/drop system for use in optical communication system is disclosed. Using semiconductor fabrication techniques, a plurality of waveguide arrays and signal carriers are substantially symmetrically arranged about an optical axis of the system. Electrode heaters are provided proximate junctions created at the intersections of selected waveguides. Using the heaters, portions of optical signals may be redirected to other waveguides. In addition, the heaters may be used to attenuate or otherwise modify signals in the waveguides. The waveguide arrays are arranged such that a plurality of signal processing operations may be performed substantially simultaneously. In a preferred embodiment, the switches and waveguide arrays are coupled with a light focusing device and a dispersion apparatus to form a switched, combined multiplexer/demultiplexer having signal attenuation and modification capabilities. | 6 |
FIELD OF THE INVENTION
The invention relates to a carbohydrate derivative, a pharmaceutical composition containing the same, as well as the use of said carbohydrate derivative for the manufacture of a medicament.
BACKGROUND OF THE INVENTION
Heparin is a commonly used anticoagulant from biological sources such as intestinal mucosa. In the presence of heparin, the inactivation of thrombin by anti-thrombin III (AT-III) is greatly accelerated, involving changes in both the conformation of heparin and AT-III on complexation. Thrombin regulates the last step in the blood coagulation cascade. The prime function of thrombin is the cleavage of fibrinogen to generate fibrin monomers, which form an insoluble gel, a fibrin clot, by cross-linking.
The structural features of heparin that are required for interacting AT-III have been subject to various investigations. There are parts in the heparin polymer which show only low affinity for AT-III, whereas other parts were found to be more important for binding to AT-III. Studies of fragmented heparin have finally resulted in the identification of a pentasaccharide fragment accounting for the minimal high-affinity structure that binds to AT-III (see e.g. Physiological Reviews, 71 (2), 488/9, 1991). In this high-affinity fragment eight sulfate groups are present. Four of the sulfate groups were found to be essential for binding to AT-III (Advances in Carbohydrate Chemistry and Biochemistry; Vol. 43; Eds. R. S. Tipson, D. Horton; Publ. Harcourt Brace Jovanovich; B. Casu (pages 51-127), paragraph 6), whereas the other further attribute to higher affinity. This finding was confirmed in synthetic analogues of the pentasaccharide fragment (see e.g. Agnew. Chem. 32 (12), 1671-1818, 1993).
The identification of the high-affinity pentasaccharide fragment inspired the preparation of synthetic analogues thereof. Small synthetic carbohydrate molecules of the glycosaminoglycan type were found to be potent and selective anti-Xa inhibitors. See for instance European patent 84,999. Later filed patents/patent applications showed that many variants of these molecules have similar and even higher activities and further improved pharmacological properties, such as the glycosaminoglycan-related carbohydrate derivatives disclosed in EP 529,715 and EP 454,220. These carbohydrate derivatives are devoid of the characteristic functional groups of glycosaminoglycans: free hydroxyl groups, N-sulfate and N-acetyl groups. Further, all of the pentasaccharides disclosed in these latter patent applications carry at least seven sulfate groups. In the field of antithrombotic oligosaccharide derivatives it was thus generally assumed that at least seven sulfate groups are required in pentasaccharide compounds in order to obtain clinically acceptable levels of antithrombotic activity.
Unexpectedly, however, a class of glycosaminoglycan-related carbohydrate derivatives has now been found having only four to six sulfate groups and which still display significant clinically effective antithrombotic activity. In addition, the compounds of this invention show fewer side effects. For example, bleeding risks are reduced and the low sulfate content of the compounds does not give rise to heparin-induced thrombocytopenia (HIT) [HIT is a severe side effect, which may be the cause of the death of a patient]. Further, compounds of this invention have a biological half-life which allows once-a-day-treatment. Once-a-day-treatment may be considered to be more favourable than, for example, once-a-week-treatment, allowing quick adaptation of the medical treatment is the condition of a patient requires so. Also hospital logistics are easier with one-a-day-treatment, as no complex dosing schemes are required for the treatment of the patients.
Thus, the compounds of the invention display an unexpected and delicately balanced pharmacological profiles.
SUMMARY OF THE INVENTION
The invention therefore relates to a carbohydrate derivative having formula I
wherein R 1 is (1-4C)alkoxy; R 2 , R 3 and R 4 are independently (1-4C)alkoxy or OSO 3 − ; the total number of sulfate groups is 4, 5 or 6; and the twisted lines represent bonds either above or below the plane of the six-membered ring to which they are attached; or a pharmaceutically acceptable salt thereof.
The compounds of the present invention are useful for treating and preventing thrombin-mediated and thrombin-associated diseases. This includes a number of thrombotic and prothrombotic states in which the coagulation cascade is activated which include, but are not limited to, deep vein thrombosis, pulmonary embolism, thrombophlebitis, arterial occlusion from thrombosis or embolism, arterial reocclusion during or after angioplasty or thrombolysis, restenosis following arterial injury or invasive cardiological procedures, postoperative venous thrombosis or embolism, acute or chronic atherosclerosis, stroke, myocardial infarction, cancer and metastasis, and neurodegenerative diseases. The carbohydrate derivatives of the invention may also be used as inhibitors of smooth muscle cell proliferation and for the treatment of angiogenesis, cancer and retrovirus infections, like HIV.
Further, the compounds of the invention may be used as anticoagulants and anticoagulant coatings in extracorporeal blood circuits, as necessary in dialysis and surgery.
The compounds of the invention may also be used as in vitro or ex vivo anticoagulants.
DETAILED DESCRIPTION OF THE INVENTION
Preferred carbohydrate derivatives according to the invention have the D-unit has the structure
R 1 is methoxy; and R 2 , R 3 and R 4 are independently methoxy or OSO 3 − .
More preferred carbohydrate derivatives are those wherein R 2 is methoxy. In particularly preferred carbohydrate derivatives R 3 is methoxy. The most preferred carbohydrate derivative is the one wherein R 4 is methoxy.
In the term (1-4C)alkoxy the (1-4C)alkyl group is a branched or unbranched alkyl group having 1 to 4 carbon atoms, such as methyl, ethyl, isopropyl, t-butyl, and the like. The most preferred alkyl group is methyl.
The counter-ions which compensate the charged moieties are pharmaceutically acceptable counter-ions, like hydrogen, or more preferably alkali or earth-alkali metal ions, like sodium, calcium, or magnesium.
The carbohydrate derivatives according to this invention may be prepared according to well known methods described and used for the synthesis of oligosaccharides. In this respect, in particular reference is made to the previously mentioned European patent EP 529,715. A suitable process for the preparation of the carbohydrate derivatives of formula I is characterized by a process wherein protected monosaccharides having different structures are coupled to give protected disaccharides, after which:
(a) protected disaccharides of one type are coupled to protected disaccharides of another type to give protected tetrasaccharides, which tetrasaccharides are coupled to a protected monosaccharide to give protected pentasaccharides; or
(b) protected monosaccharides are coupled to protected disaccharides to give protected trisaccharides, which are further coupled to protected disaccharides to give protected pentasaccharides;
after which the protective groups are cleaved and free hydroxy groups are sulfated, after which the compound obtained is optionally converted into a pharmaceutically acceptable salt.
The monosaccharides are D-glucose, D-mannose, L-idose, D-glucuronic acid or L-iduronic acid, suitably functionalized with the required alkyl groups or by temporarily protective groups. Suitable protective groups are well known in the art. Preferred protective groups include benzyl and acetyl for hydroxy groups, and benzyl for the carboxylate groups of uronic acids. Other protective groups, such as benzoyl, levulinyl, alkoxyphenyl, chloroacetyl, trityl, and the like may be used with equal success. Coupling of the saccharide is performed in a manner known in the art, e.g. deprotection of the 1-position of the glycosyl-donor, and/or activation of this position (e.g. by making a bromide, pentenyl, fluoride, thioglycoside, or trichloroacetimide derivative) and coupling the activated glycosyl-donor with an optionally protected glycosyl-acceptor.
For the treatment of venous thrombosis or for the inhibition of smooth muscle cell proliferation the compounds of the invention may be administered enterally or parenterally, and for humans preferably in a daily dosage of 0.001-10 mg per kg body weight. Mixed with pharmaceutically suitable auxiliaries, e.g. as described in the standard reference, Gennaro et al., Remington's Pharmaceutical Sciences (18th ed., Mack Publishing Company, 1990, see especially Part 8: Pharmaceutical Preparations and Their Manufacture), the compounds may be compressed into solid dosage units, such as pills, tablets, or be processed into capsules or suppositories. By means of pharmaceutically suitable liquids the compounds can also be applied as an injection preparation in the form of a solution, suspension, emulsion, or as a spray, e.g. a nasal spray.
For making dosage units, e.g. tablets, the use of conventional additives such as fillers, colorants, polymeric binders and the like is contemplated. In general any pharmaceutically acceptable additive which does not interfere with the function of the active compounds can be used. Suitable carriers with which the compositions can be administered include lactose, starch, cellulose derivatives and the like, or mixtures thereof, used in suitable amounts.
The invention is further illustrated by the following examples.
EXAMPLES
Preparation of Example I (Compound 32 )
Synthesis of GH Disachharide 16 (Scheme 1+2)
Compound 2
Compound 1 (60 g; commercially available) was dissolved in N,N-dimethylformamide (858 ml) together with benzyl bromide (50.5 ml). After cooling to +10° C. a 20% aqueous solution of sodium hydroxide was added dropwise. After stirring for 1 hour the temperature was raised to 20° C. and the mixture was stirred another 20 hours. The solution was then poured into a mixture of icewater and toluene and extracted. The organic layer was concentrated and the crude product purified by cristallysation to give 30.0 g of compound 2 .
TLC: Rf=0.60, toluene/ethyl acetate: 7/3, v/v
Compound 3
Compound 2 (26.4 g) was dissolved in N,N-dimethylformamide (211 ml) and cooled in ice. Sodium hydride (2.5 g) was added under nitrogen atmosphere. Then 4-methoxy benzyl chloride (13.3 g) was added dropwise and the mixture was stirred for 1 hour at room temperature. The mixture was then diluted with ethyl acetate, washed with water (2×) and concentrated to give 40.7 g of crude compound 3 .
TLC: Rf=0.80, toluene/ethyl acetate: 7/3, v/v
Compound 4
Compound 3 (34.9 g) was dissolved in 60% aq. acetic acid and stirred for 4 hours at 60° C. The mixture was diluted with toluene and concentrated. Purification by silicagel chromatography gave 26.4 g of compound 4 .
TLC: Rf=0.07, toluene/ethyl acetate: 7/3, v/v
Compound 5
Compound 4 (26.4 g) was dissolved in dichloromethane (263 ml) under nitrogen atmosphere. Trimethyloxonium tetrafluoroborate (11.6 g) and 2,6-di-t-butyl-4-methylpyridine (17.4 g) were added at room temperature. After 4 hours the mixture was poured into ice-water and extracted with dichloromethane. The organic layer was washed with sodium hydrogencarbonate and evaporated. Purification of the crude product by silicagel chromatography gave 18.5 g of compound 5 .
TLC: Rf=0.25, toluene/ethyl acetate: 7/3, v/v
Compound 7
Compound 6 (3-methyl-1,2,4,6-tetraacetyl-idose) (48.4 g) was dissolved in toluene (175 ml). Under nitrogen atmosphere ethanethiol (20 ml) and boron trifluoride diethyl etherate (1M in toluene; 134 ml) were added. After stirring for 1 hour aqueous sodium hydrogencarbonate (400 ml) was added and the mixture was stirred for another hour. The mixture was then poured into ethyl acetate. The organic layer was washed twice with water and concentrated. Purification by silicagel chromatography gave 29.6 g of compound 7 .
TLC: Rf=0.45, toluene/ethyl acetate: 6/4, v/v
Compound 8
Compound 5 (17.5 g) and compound 7 (28.2 g) were dissolved in toluene (525 ml) under nitrogen atmosphere. After addition of powdered molsieves (4 Å) the reaction was cooled to −20° C. A freshly prepared 0.1 M solution of N-iodosuccinimide (17.4 g) and trifluoromethanesulphonic acid (1.38 ml) in dioxane/dichloromethane (1/1 v/v) were added dropwise under continuous nitrogen flux. After 10 minutes the red reaction mixture was filtered and washed successively with aqueous sodium thiosulphate and aqueous sodium hydrogencarbonate. The organic layer was concentrated in vacuo and 30.0 g of compound 8 isolated.
TLC: Rf=0.45, dichloromethane/ethyl acetate: 8/3, v/v
Compound 9
Compound 8 (30.0 g) was dissolved in 460 ml methanol/dioxane (1/1, v/v) and potassium butanolate was added for saponification. After 15 minutes the mixture was neutralised with Dowex 50WX8H + -form and concentrated in vacuo. Purification was established by silicagel chromatography to give 17.4 g of compound 9 .
TLC: Rf=0.25, dichloromethane/methanol: 95/5, v/v
Compound 10
Under nitrogen atmosphere compound 9 (17.4 g) was dissolved in N,N-dimethyl-formamide (77 ml). 1,2-dimethoxypropane (26 ml) and p-toluenesulfphonic acid where added and the mixture was stirred for 30 minutes. Diluting the mixture with aqueous sodium hydrogencarbonate and extracting it with ethyl acetate gave 19.7 of compound 10 after evaporation of the solvent.
TLC: Rf=0.45, dichloromethane/methanol: 95/5, v/v
Compound 11
Compound 10 (18.5 g) was dissolved in N,N,-dimethylformamide (24.4 ml) and cooled to 0° C. Under nitrogen atmosphere sodium hydride (1.47 g; 60% dispersion in oil) and iodomethane (2.36 ml) where added. After 1 hour excess of sodium hydride was neutralised, the mixture extracted with dichloromethane and concentrated to give 20.0 g of compound 11 .
TLC: Rf=0.85, dichloromethane/methanol: 95/5, v/v
Compound 12
Compound 11 (18.4 g) was dissolved in dichloromethane (838 ml) and water (168 ml). 2,3-Dichloro-5,6-dicyano-1,4-benzoquinone (7.1 g) was added and the mixture was stirred for 18 hours at 4° C. The mixture was poured into aqueous sodium hydrogencarbonate and extracted with dichloromethane. Concentration of the organic layer gave 12.7 g of compound 12 .
TLC: Rf=0.40, dichloromethane/methanol: 95/5, v/v
Compound 13
Compound 12 was converted to the title compound according to the same procedures described for the preparation of compound 11 .
TLC: Rf=0.48, toluene/ethyl acetate: 1/1, v/v
Compound 14
After dissolving compound 13 (2.5 g) in acetic acid (14.6 ml) and water (6.1 ml) the mixture was stirred overnight at roomtemperature. Coevaporation with toluene and purification by silicagel chromatography gave 1.9 g of compound 14 .
TLC: Rf=0.31, ethyl acetate, v/v
Compound 15
To a solution of compound 14 (1.7 g) in dichloromethane (9 ml) were added 2,2,6,6-tetramethyl-1-piperidinyloxy (5 mg), saturated sodium hydrogen carbonate solution (5.8 ml), potassium bromide (32 mg) and tetrabutylammonium chloride (42 mg). The mixture was cooled to 0° C. and a mixture of saturated sodium chloride solution (6.5 ml) saturated sodium hydrogen carbonate solution (3.2 ml) and sodium hypochlorite (1.3 M; 7.3 ml) was added during 15 minutes. After 1 hour stirring the mixture was diluted with water and extracted (3 times) with dichloromethane. The organic layer was washed with brine, dried on magnesium sulfate, filtered and evaporated to dryness to give 1.74 g of crude compound 15 .
TLC: Rf=0.14, dichloromethane/methanol: 9/1, v/v
Methyl O-(benzyl 2,3-Di-O-methyl-α-L-idopyranosyluronate)-(1→4)-2-O-benzyl-3,6-Di-O-methyl-α-D-glucopyranoside 16
To a solution of 1.74 g of compound 15 in N,N-dimethylformamide was added under nitrogen atmosphere 1.68 ml of benzylbromide and 1.1 g of potassium hydrogen carbonate. After stirring the solution for 90 minutes water was added and the mixture extracted with ethyl acetate. After evaporation of the organic layer and purification by silicagel chromatography 1.64 g of compound 16 was isolated.
TLC: Rf=0.50, toluene/ethyl acetate: 1/1, v/v
Synthesis of EF-disaccharide 25 (Scheme 2+3)
Compound 17
Compound 12 (10.5 g) was dissolved in dry N,N-dimethylformamide (178 ml), cooled to 0° C. under nitrogen atmosphere. Sodium hydride (1.91 g; 60% dispersion in oil) was added after which benzylbromide (3.3 ml) was added dropwise. After 30 minutes the reaction was complete and the excess sodium hydride was neutralised. Water was added and the mixture extracted twice with ethyl acetate. Evaporation of the solvent gave 13.6 g of compound 17 .
TLC: Rf=0.50, toluene/ethyl acetate: 1/1, v/v
Compound 18
Compound 17 was converted to the title compound according the same procedures described for the preparation of compound 14 .
TLC: Rf=0.68, dichloromethane/methanol: 9/1, v/v
Compound 19
Compound 18 was converted to the title compound according the same procedures described for the preparation of compound 15 .
TLC: Rf=0.14, dichloromethane/methanol: 9/1, v/v
Compound 20
Compound 19 was converted to the title compound according the same procedures described for the preparation of compound 16 .
TLC: Rf=0.38, dichloromethane/methanol: 85/15, v/v
Compound 21
Compound 20 (9.9 g) was dissolved in 300 ml methanol (dry) and refluxed under nitrogen atmosphere. A 1 M solution of sodium methoxide (65.2 ml) was added dropwise and stirred for 3 hours. The temperature was then cooled to room temperature and 1N sodium hydroxide (22.2 ml) was added and stirred for 90 minutes. Neutralisation with Dowex 50WX8H + form and evaporation of the solvents gave the crude residue.
N,N-dimethylformamide (192 ml) and powdered molsieves (4 Å) were added under nitrogen atmosphere. Potassium hydrogencarbonate (3.2 g) and benzylbromide (4.8 ml) were added and the mixture stirred for 5 hours after which ethyl acetate was added and the mixture washed with water. Evaporation of the solvent and purification of the rude product by silicagel chromatography gave 6.19 g of compound 21 and 1.88 g of recovered compound 20 .
TLC: Rf=0.74, dichloromethane/methanol: 9/1, v/v
Compound 22
Compound 21 (6.2 g) was dissolved in 40 ml of dioxane. Levulinic acid (2.1 g), dicyclohexyl carbodiimide (3.75 g) and 4-dimethylaminopyridine (0.2 g) where added and the mixture stirred for 2 hours under nitrogen atmosphere. Ether (95 ml) was added and the precipitate filtered off. The organic layer was washed with aqueous potassium hydrogensulphate and concentrated. Cristallisation from diethyl ether/heptane gave 6.2 g of compound 22 .
TLC: Rf=0.26, dichloromethane/acetone: 95/5, v/v
Compound 23
Compound 22 (6.1 g) was dissolved in acetic anhydride (256 ml) under nitrogen atmosphere and cooled to −20° C. A mixture of sulphuric acid (4.9 ml) in acetic anhydride (49 ml) was added dropwise during 30 minutes. After 60 minutes sodium acetate was added until the pH of the mixture was neutral. Ethyl acetate and water where added and the organic layer concentrated. Purification by silicagel chromatography gave 4.2 g of compound 23 .
TLC: Rf=0.63, dichloromethane/acetone: 9/1, v/v
Compound 24
Compound 23 (4.2 g) was dissolved in tetrahydrofuran (42 ml) and piperidine (4.1 ml) was added. The mixture was stirred overnight at room temperature. Ethyl acetate was added and the mixture washed with 0.5 N hydrochloric acid. The organic layer was concentrated and the residue purified by silicagel chromatography to give 3.2 g of compound 24 .
TLC: Rf=0.33, dichloromethane/ethyl acetate: 1/1, v/v
O-(benzyl 2,3-di-O-methyl-4-O-levulinoyl-β-D-glucopyranosyluronate)-(1→4)-3-O-acetyl-2-O-benzyl-6-O-methyl-D-glucopyranosyl Trichloroacetimidate 25
Compound 24 (1.59 g) was dissolved in dichloromethane under nitrogen atmosphere. Trichloroacetonitril (1.1 ml) and cesium carbonate (72 mg) were added and the mixture stirred for 1 hour. The cesium carbonate was filtered off and the filtrate concentrated. Purification by silicagel chromatography gave 1.57 of compound 25 .
TLC: Rf=0.60, toluene/ethyl acetate: 3/7, v/v
Synthesis of EFGH-tetrasaccharide 27 (Scheme 4)
Compound 26
A mixture of compound 16 (0.530 mg) and compound 25 (0.598 mg) was dried by coevaporation with dry toluene and dissolved in 8.2 ml of dry dichloromethane. Powdered molsieves (4 Å) was added and the mixture was cooled to −20° C. under nitrogen atmosphere and stirred for 30 minutes. To the resulting suspension was added trimethylsilyl trifluoromethanesulphonate (15 mol % in relation to compound 25 ). After stirring for 10 minutes sodium hydrogencarbonate was added, the mixture was filtered and water and dichloromethane were added. The organic layer was then extracted, concentrated and the crude product purified by silicagel chromatography to give 0.62 g of compound 26 .
TLC: Rf=0.47, toluene/ethyl acetate: 3/7, v/v
Methyl-O-(Benzyl 2,4-di-O-dimethyl-β-D-glucopyranosyluronate)-(1-4)-O-(3-O-acetyl-2-O-benzyl-6-O-methyl-α-D-glucopyranosyl)-(1→4)-O-(benzyl 2,3-di-O-methyl-α-L-idopyranosyluronate)-(1→4)-2-O-benzyl-3,6-di-O-methyl-α-D-glucopyranoside 27
To a solution of compound 26 (0.58 g) in pyridine was added a mixture of 2.76 ml acetic acid, 0.32 ml hydrazine hydrate in 2.1 ml pyridine. After 9 minutes, water and dichloromethane where added and the organic layer washed with 1 N hydrochloric acid and aqueous sodium hydrogencarbonate. Purification by silicagel chromatography gave 0.27 g of compound 27 .
TLC: Rf=0.45, toluene/ethyl acetate: 3/7, v/v
Synthesis of DEFGH-pentasaccharide 32 (Scheme 4+5) Example I
Compound 29
A mixture of compound 27 (150 mg) and 76 mg of compound 28 (Ref: Bioorganic & Medicinal Chemistry, vol 2, no 11, 1267-1280, 1994) was dried by coevaporation with dry toluene and dissolved in 7.5 ml of dry dichloromethane. Under nitrogen atmosphere powdered molsieves (4 Å) was added and the mixture cooled to −20° C. After stirring for 20 minutes trimethylsilyl trifluoromethanesulphonate (15 mol % in relation to compound 28 ) was added. After stirring for 30 minutes aqueous sodium hydrogen-carbonate was added. The mixture was filtered and the organic layer was washed with water. Concentration of the solvent gave the crude product which was purified by silicagel chromatography to give 136 mg of compound 29 .
TLC: Rf=0.33, toluene/ethyl acetate: 4/6, v/v
Compound 30
Compound 29 was diluted in a mixture of t-butanol (8 ml) and water (1 ml). To the solution 122 mg of 10% palladium on charcoal was added and the mixture was stirred overnight under hydrogen atmosphere. The palladium on charcoal was filtered and the solution was concentrated to give 84.5 mg of compound 30 .
TLC: Rf=0.49, ethyl acetate/pyridine/acetic acid/water: 13/7/1.6/4, v/v
Compound 31
Compound 30 (84.5 mg) was dissolved in 5 ml of 0.3 N sodium hydroxide and stirred and stirred for 3 hours. The reaction mixture was then neutralised with 0.5 N hydrochloric acid and evaporated. The residu was desalted on a Sephadex G25 column with water/acetonitril: 9/1 (v/v) and passed through a short column of Dowex 50WX8H + -form. After evaporation 75.6 mg of compound 31 was isolated.
TLC: Rf=0.43, ethyl acetate/pyridine/acetic acid/water: 8/7/1.6/4, v/v
Methyl O-(2,3,4-tri-O-methyl-6-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-β-D-glucopyranosyluronic acid)-(1→4)-O-(6-O-methyl 2,3-di-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-α-L-idopyranosyluronic acid)-(1→4)-3,6-di-O-methyl-2-O-sulfo-α-D-glucopyranoside, Hexasodium Salt 32
Compound 31 (30.6 mg) was dissolved in 2.15 ml N,N-dimethylformamide (destilled; dry) and triethylamine sulfurtrioxide complex (120 mg) was added under nitrogen atmosphere. The mixture was stirred overnight at 55° C. A suspension of sodium hydrogencarbonate in water was added. The mixture was stirred for 1 hour at room temperature and the solvent evaporated. The residu was dissolved in water (2 ml) and desalted on a Sephadex G25-column with water/acetonitril: 9/1 (v/v). The isolated product was eluted on a Dowex 50WX8Na + -column with water to give the 42.5 mg of pentasaccharide compound 32 .
[α] 20 D =+56.8 (c=1, H 2 O)
Anomeric protons chemical shifts: 5.32, 5.22, 4.97, 4.89 and 4.24 ppm.
Preparation of Example II (Compound 38 )
Synthesis of EFGH-tetrasaccharide 34 (Scheme 4)
Compound 33
Compound 25 and compound 20 were coupled to give the title compound according the same procedures described for the preparation of compound 26 .
TLC: Rf=0.47, toluene/ethyl acetate: 3/7, v/v
Methyl-O-(Benzyl 2,4-di-O-dimethyl-β-D-glucopyranosyluronate)-(1→4)-O-(3-O-acetyl-2-O-benzyl-6-O-methyl-α-D-glucopyranosyl)-(1→4)-O-(benzyl 2,3-di-O-methyl-α-L-idopyranosyluronate)-(1→4)-2,3-di-O-benzyl-6-O-methyl-α-D-glucopyranoside 34
Compound 33 was converted to the title compound according the same procedures described for the preparation of compound 27 .
TLC: Rf=0.39, heptane/ethyl acetate: 3/7, v/v
Synthesis of DEFGH-pentasaccharide 38 (Scheme 4+5) (Example II)
Compound 35
Compound 34 and compound 28 were coupled to give the title compound according the same procedures described for the preparation of compound 29 .
TLC: Rf=0.60, toluene/ethyl acetate: 3/7, v/v
Compound 36
Compound 35 was converted to the title compound according the same procedure described for the preparation of compound 30 .
TLC: Rf=0.39, ethyl acetate/pyridine/acetic acid/water: 13/7/1.6/4, v/v
Compound 37
Compound 36 was converted to the title compound according the same procedures described for the preparation of compound 31 .
TLC: Rf=0.32, ethyl acetate/pyridine/acetic acid/water: 13/7/1.6/4, v/v
Methyl O-(2,3,4-tri-O-methyl-6-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-β-D-glucopyranosyluronic acid)-(1→4)-O-(6-O-methyl-2,3-di-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-α-L-idopyranosyluronic acid)-(1→4)-6-O-methyl-2,3-di-O-sulfo-α-D-glucopyranoside, Heptasodium Salt 38
Compound 37 was converted to the title compound according the procedures described for the preparation of compound 32 .
[α] 20 D =+53.6 (c=1, H 2 O)
Anomeric protons chemical shift: 5.32, 5.23, 4.99, 4.9 and 4.23 ppm.
Preparation of Example III (Compound 56 )
Synthesis of GH-disaccharide 50 (Scheme 1+2)
Compound 39
Compound 2 was converted to the title compound according the same procedures described for the preparation of compound 11 .
TLC: Rf=0.52, dichloromethane/acetone: 98/2 v/v
Compound 40
Compound 39 (32.0 g) was dissolved in methanol (538 ml). p-Toluenesulfonic acid (1.57 g) was added and the mixture was stirred for 1.5 hour at room temperature. After neutralization with triethylamine the mixture was concentrated. Purification by silicagel chromatography gave 11.9 g of compound 40 .
TLC: Rf=0.56, dichloromethane/methanol: 9/1, v/v
Compound 41
Compound 40 was converted to the title compound according the same procedures described for the preparation of compound 5 .
TLC: Rf=0.18, toluene/ethyl acetate: 7/3, v/v
Compound 42
Compound 6 was converted to the title compound according the same procedure described for compound 24 .
Compound 43
Compound 42 was converted to the title compound according the same procedures described for the preparation of compound 25 .
Compound 44
The coupling reaction of compound 43 with compound 41 was performed under the same conditions as described for compound 26 .
TLC: Rf=0.28, toluene/ethyl acetate: 6/4, v/v
Compound 45
Compound 44 was converted to the title compound according the same procedures described for the preparation of compound 9 .
TLC: Rf=0.09, toluene/ethyl acetate: 3/7, v/v
Compound 46
Compound 45 was converted to the title compound according the same procedures described for the preparation of compound 10 .
TLC: Rf=0.52, ethyl acetate
Compound 47
Compound 46 (10.4 g) was dissolved in pyridine (dry) (102 ml) under nitrogen atmosphere. A mixture of acetic anhydride (34 ml) and pyridine (dry) (102 ml) and 10 mg of 4-dimethylaminopyridine was added. After stirring for 1 hour at room temperature the reaction mixture was concentrated and coevaporated with dry toluene to give 11.9 g of compound 47 .
TLC: Rf=0.50, toluene/ethyl acetate: 1/1, v/v
Compound 48
After dissolving compound 47 (11.9 g) in methanol (90 ml), 180 mg of p-toluenesulphonic acid was added and the mixture was stirred overnight at room temperature. The mixture was diluted with ethyl acetate, washed with water (2×) and concentrated. Purification of the crude product by silicagel chromatography gave 6.2 g of compound 48 .
TLC: Rf=0.28, toluene/ethyl acetate: 3/7, v/v
Compound 49
Compound 48 was converted to the title compound according the same procedures described for the preparation of compound 15 .
TLC: Rf=0.24, dichloromethane/methanol: 9/1, v/v
Methyl O-(Benzyl 2-O-acetyl-3-O-methyl-α-L-idopyranosyluronate)-(1→4)-2-O-benzyl-3,6-di-O-methyl-α-D-glucopyranoside 50
Compound 49 was converted to the title compound according the same procedures described for the preparation of compound 16 .
TLC: Rf=0.37, dichloromethane/methanol: 9/1, v/v
Synthesis of EFGH-tetrasaccharide 52 (Scheme 4)
Compound 51
Compound 25 and compound 50 were coupled to give the title compound according the same procedures described for the preparation of compound 26 .
TLC: Rf=0.52, dichloromethane/methanol: 98/2, v/v
Methyl-O-(Benzyl 2,4-di-O-dimethyl-β-D-glucopyranosyluronate)-(1→4)-O-(3-O-acetyl-2-O-benzyl-6-O-methyl-α-D-glucopyranosyl-(1→4)-O-(benzyl 2-O-acetyl-3-O-methyl-α-L-idopyranosyluronate)-(1→4)-2-O-benzyl-3,6-di-O-methyl-α-D-glucopyranoside 52
Compound 51 was converted to the title compound according the same procedures described for the preparation of compound 27 .
TLC: Rf=0.26, dichloromethane/methanol: 98/2, v/v
Synthesis of DEFGH-pentasaccharide 56 (Scheme 4+5) (Example III)
Compound 53
Compound 28 and compound 52 were coupled to give the title compound according the same procedures described for the preparation of compound 29 .
TLC: Rf=0.63, dichloromethane/methanol: 98/2, v/v
Compound 54
Compound 53 was converted to the title compound according the same procedures described for the preparation of compound 30 .
TLC: Rf=0.51, dichloromethane/methanol: 8/2, v/v
Compound 55
Compound 54 was converted to the title compound according the same procedures described for the preparation of compound 31 .
TLC: Rf=0.32, ethyl acetate/pyridine/acetic acid/water: 10/7/1.6/4, v/v
Methyl O-(2,3,4-tri-O-methyl-6-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-β-D-glucopyranosyluronic acid)-(1→4)-O-(6-O-methyl-2,3-di-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(3-O-methyl-2-O-sulfo-α-L-idopyranosyluronic acid)-(1→4)-3,6-di-O-methyl-2-O-sulfo-α-D-glucopyranoside, Heptasodium Salt 56
Compound 55 was converted to the title compound according the same procedures described for the preparation of compound 32 .
[α] 20 D =+50.2 (c=1.05, H 2 O)
Anomeric protons chemical shifts: 5.32, 5.29 and 4.89 ppm.
Preparation of Example IV (Compound 80 )
Synthesis of EF-disaccharide 66 (Scheme 6)
Compound 58
Et 3 N (43 ml, 0.3 mmol), 4-dimethylaminopyridine (156 mg, 1.3 mmol) and Ac 2 O (23 ml, 0.29 mol) were added to a solution of 57 (36.2 g, 0.128 mol) (Petroni et al. Aust. J. Chem. 1988, 41, 91-102) in CH 2 Cl 2 (360 ml). After 30 min. the mixture was successively washed with 5% aq KHSO 4 , H 2 O, saturated aqueous NaHCO 3 , H 2 O and dried (Na 2 SO 4 ). The evaporation gave crude 58 : TLC, R f 0.41, 3:1 cyclohexane/EtOAc.
Compound 59
Ethanolamine (4.9 ml, 80 mmol)) was added, at +4° C., to a solution of crude 58 (11.8 g, 32 mmol) in THF (220 ml). After 16 h at +4° C., trichloroacetonitrile (65 ml, 644 mmol) and K 2 CO 3 (8.3 g, 64.4 mmol) were added under argon to the above mixture. After 16 h at room temperature, the solution was filtered and concentrated. Column chromatography (4:1 cyclohexane/EtOAc) afforded 59 in 79% yield: TLC R f 0.49, 1:1 cyclohexane/EtOAc.
Compound 61
A solution of trimethylsilyl triflate (0.04 M in CH 2 Cl 2 ; 96 ml, 3.8 mmol) was added dropwise, under argon, to a cooled (−20° C.) solution of the donor imidate 59 (11.93 g, 25 mmol) and acceptor 60 (9.2 g, 19.8 mmol) (P. J. Garegg, H. Hultberg Carbohydr. Res. 1961, 93, C10) in CH 2 Cl 2 (190 ml) containing 4 Å powdered molecular sieves. After 30 minutes solid NaHCO 3 was introduced, and the solution was filtered, washed with water, dried (Na 2 SO 4 ) and concentrated. The residue crystallized in Et 2 O gave 61 (82% yield). mp: 138° C.
Compound 62
Sodium (373 mg, 0.65 mmol) was added to a solution of compound 61 (1 g, 1.3 mmol) in 2:1 methanol/CH 2 Cl 2 (ml). The mixture was stirred for 1 h at room temperature, and then neutralized with Dowex 50 H + resin, filtered and concentrated to afford crude 62 .
Compound 63
NaH (40.5 mg, 1.68 mmol) was added portionwise to a cooled (0° C.) solution of crude 62 (950 mg,) and MeI (0.1 ml, 1.55 mmol) in DMF (9 ml). After 2 h at room temperature, MeOH was introduced, and the mixture was poured into H 2 O. The product was extracted with EtOAc, washed with H 2 O, dried (Na 2 SO 4 ) and concentrated. Column chromatography (3:1 cyclohexane/EtOAc) of the residue gave pure 63 (86% yield from 62 ): mp 137° C. (Et 2 O).
Compound 64
A solution of 63 (1.16 g, 1.56 mmol) in 1:3 H 2 O/MeOH (40 ml) was heated at 80° C. in presence of p-toluenesulfonic acid (230 mg, 1.56 mmol). After 3 h, the mixture was neutralized with NaHCO 3 and concentrated. Column chromatography (3:1 cyclohexane/acetone) of the residue gave 64 (89% yield): TLC R f 0.28, 2:1 cyclohexane/acetone.
Methyl O-(benzyl 2,3-di-O-methyl-β-D-glucopyranosyluronate)-(1→4)-2,3,6-tri-O-benzyl-α-D-glucopyranoside 66
To a solution of 64 (860 mg, 1.3 mmol) in CH 2 Cl 2 (4 ml) were added 2,2,6,6-tetramethyl-1-piperidinyl oxy (2.3 mg), saturated aqueous NaHCO 3 (2.5 ml), KBr (13.5 mg) and tetrabutylammonium chloride (18 mg). To the above cooled (0° C.) solution was added the mixture of solutions saturated aqueous NaCl (2.8 ml), saturated aqueous NaHCO 3 (1.4 ml) and NaOCl (1.3 M, 3.2 ml). After 1 h, the mixture was extracted with CH 2 Cl 2 , washed with H 2 O, dried (Na 2 SO 4 ) and concentrated to give the crude acid 65 .
The crude above acid in DMF was treated with BnBr (1.6 ml, 13 mmol) and KHCO 3 (650 mg, 6.5 mmmol). After 16 h, the product was extracted with EtOAc, washed with H 2 O, dried (Na 2 SO 4 ) and concentrated to give 66 in 77% yield.
Synthesis of DEF-trisaccharide 70 (Scheme 7)
Compound 67
A solution of trimethylsilyl triflate (0.04 M in CH 2 Cl 2 ; 1.88 ml, 0.075 mmol) was added dropwise, under argon, to a cooled (−20° C.) solution of 6-O-acetyl-2,3,4-tri-O-methyl-D-glucopyranose trichloroacetimidate 28 (290 mg, 0.711 mmol) (P. Westerduin et al. Bioorg Med. Chem. 1994, 2, 1267-83) and acceptor 66 (300 mg, 0.4 mmol) in CH 2 Cl 2 (20 ml) containing 4 Å powdered molecular sieves. After 30 minutes solid NaHCO 3 was introduced, and the solution was filtered and concentrated. Column chromatography (3:1 toluene/EtOAc) of the residue gave pure 67 (56% yield): TLC R f 0.32, 3:2 toluene/EtOAc.
Compound 68
To a solution of 67 (201 mg, 0.20 mmol) in acetic anhydride (7.6 ml) at −20° C. a mixture of concentrated sulfuric acid in acetic anhydride (1.5 ml, 0.1:1 v/v) was added. After stirring 1 h sodium acetate (780 mg) was added. The mixture was diluted was EtOAc, washed with H 2 O, dried (Na 2 SO 4 ) and concentrated to give, after column chromatography (1:1 toluene/EtOAc), 68 (82% yield): TLC R f 0.32, 1:1 toluene/EtOAc.
Compound 69
Benzylamine (0.58 ml, 5.26 mmol) was added to a solution of the 68 (125.4 mg) in THF (5 ml). After 7 h at room temperature the solution was washed with 1 M aqueous HCl, H 2 O, dried, and concentrated. Column chromatography (3:2 toluene/EtOAc) afforded pure 69 (75% yield): TLC R f 0.33, 2:3 toluene/EtOAc.
O-(6-O-acetyl-2,3,4-tri-O-methyl-α-D-glucopyranosyl)-(1→4)-O-(benzyl 2,3-di-O-methyl-β-D-glucopyranosyluronate)-(1→4)-3,6-di-O-acetyl-2-O-benzyl-D-glucopyranosyl Trichloroacetimidate 70
Trichloroacetonitrile (69 μl, 0.675 mmol), and cesium carbonate (66 mg, 0.202 mmol), were added under argon to a solution of 69 (89.2 mg, 0112 mmol) in CH 2 Cl 2 (2 ml). After 2 h the solution was filtered and concentrated. Column chromatography of the residue (1:1 toluene/EtOAc) afforded 70 (88% yield): TLC R f 0.44, 1:1 toluene/EtOAc.
Synthesis of GH-disaccharide 76 (Scheme 2)
Compound 72
Sodium methoxide (570 mg, 106 mmol) was added to a solution of compound 71 (2.5 g, 3.53 mol) (M. Petitou er al. J. Med. Chem. 1997, 40, 1600-1607) in 1:1 methanol/CH 2 Cl 2 (35 ml). After 2 h Dowex 50 H + resin was introduced until neutralisation and filtered. After concentration, column chromatography (2:1 cyclohexane/EtOAc) of the residue gave 72 (100% yield): TLC R f 0.32, 2:1 cyclohexane/EtOAc.
Compound 73
MeI (0.41 ml, 6.61 mmol) was added, at 0° C., to a solution of 72 (2 g, 3.3 mmol), and NaH (0.12 g, 5 mmol), in THF (20 ml). After 2 h MeOH was introduced dropwise, and after 15 min the product was extracted with CH 2 Cl 2 . The solution was washed with H 2 O, dried (Na 2 SO 4 ), and concentrated. Column chromatography (5:1 cyclohexane/EtOAc) gave pure 73 (89% yield): [α] D +12° (c 1; CH 2 Cl 2 ).
Compound 74
Aqueous CF 3 COOH (70%, 3.14 ml) was added to a solution of 73 (1.76 g, 2.84 mmol) in CH 2 Cl 2 (16 ml). After 50 min at room temperature the solution was diluted with CH 2 Cl 2 , washed with cold saturated aqueous NaHCO 3 , H 2 O, and dried (Na 2 SO 4 ). After concentration, column chromatography (11:2 CH 2 Cl 2 /acetone) of the residue yielded 74 in 88% yield): [α] D +10° (c 1; CH 2 Cl 2 ).
Methyl O-(benzyl 2,3-di-O-methyl-α-L-idopyranosyluronate)-(1→4)-2,6-di-O-benzyl-3-O-methyl-α-D-glucopyranoside 76
To a solution of 74 (1.39 g, 2.4 mmol) in THF (8 ml) were added 2,2,6,6-tetramethyl-1-piperidinyl oxy (37.4 mg), saturated aqueous NaHCO 3 (14.4 ml), KBr (120 mg) and tetrabutylammonium chloride (180 mg). To the above cooled (0° C.) solution was added the mixture of solutions saturated aqueous NaCl (2.8 ml), saturated aqueous NaHCO 3 (1.4 ml) and NaOCl (1.3 M, 3.2 ml). After 1 h, the mixture was extracted with CH 2 Cl 2 , washed with H 2 O, dried (Na 2 SO 4 ) and concentrated to give the crude acid 75 .
The above crude acid 75 in DMF (31 ml) was treated with BnBr (2.84 ml, 23.9 mmol) and KHCO 3 (1.2 g, 12 mmmol). After 16 h, the product was extracted with EtOAc, washed with H 2 O, dried (Na 2 SO 4 ). After concentration, column chromatography (3:2 cyclohexane/EtOAc) of the residue gave 76 (78% yield from 74 ): [α] D +7.3° (c 1.1; CH 2 Cl 2 ).
Synthesis of DEFGH-pentasaccharide 80 (Scheme 8) (Example IV)
Compound 77
Trimethylsilyl triflate (170 μL, 0.0068 mmol) was added under argon to a stirred, cooled (−20° C.) solution of imidate 70 (91 mg, 0.097 mmol), and 76 (66.2 mg, 0.097 mmol), in CH 2 Cl 2 (2 ml) containing 4 Å molecular sieves. After 30 min, solid NaHCO 3 (0.1 g) was introduced, and stirring was prolonged overnight. The solution was filtered, washed with H 2 O, dried, and concentrated. Column chromatography (2:1 cyclohexane/acetone) provided the pentasaccharide 77 (71.6% yield): TLC R f 0.4, 2:1 cyclohexane/acetone.
Methyl O-(2,3,4-tri-O-methyl-6-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-β-D-glucopyranosyluronic acid)-(1→4)-O-(2,3,6-tri-O-sulfo-α-D-glucopyranosyl)-(1→4)-O-(2,3-di-O-methyl-α-L-idopyranosyluronic acid)-(1→4)-3-O-methyl-2,6-di-O-sulfo-α-D-glucopyranoside, Octasodium Salt 80
A solution of 77 (50 mg, 0.032 mmol) in DMF (5 ml) was stirred during 16 h under a weak stream of H 2 in the presence of 10% Pd/C catalyst (50 mg). After filtration, the solution was concentrated to give 78 .
Aqueous NaOH (5 M, 0.46 ml) was added to a solution of the above crude compound in MeOH (26 ml). After 5 h Dowex 50 H + was introduced until neutral pH. The solution was concentrated, and the residue was layered on top of a Sephadex G 25 column eluted with H 2 O. Concentration of the pooled fractions gave crude 79 .
Et 3 N/SO 3 complex (174 mg, 0.96 mmol) was added to a solution of the above compound in DMF (6 ml), and the solution was heated at 55° C. for 20 h. NaHCO 3 (0.33 mg dissolved in H 2 O) was then introduced, and the solution was layered on top of a sephadex G 25 column (1.6×100 cm) equilibrated in 0.2 M NaCl. The fractions were pooled, concentrated, and desalted on the same gel filtration column, equilibrated in H 2 O. Lyophilisation then gave pentasaccharide 80 (95% yield from 77 ): [α] D +49° (c 1; H 2 O).
Example V
The biological activity of the compounds of the present invention can be determined in the anti-factor Xa assay.
Activated Factor X (Xa) is a factor in the coagulation cascade. The anti-Xa activity of compounds of the present invention was assessed by measuring spectrophotometrically the rate of hydrolysis of the chromogenic substrate s-2222 exerted by Xa. This assay for anti-Xa activity in a buffer system was used to assess the IC 50 -value of the test compound.
Reference compound: benzamidine
Test medium: Tromethamine-NaCl-polyethylene glycol 6000 (TNP) buffer
Vehicle: TNP buffer.
Solubilisation can be assisted with dimethylsulphoxide, methanol, ethanol, acetonitrile or tert.-butyl alcohol which are without adverse effects in concentrations up to 1% (for DMSO) and 2.5% (for the other solvents) in the final reaction mixture.
Technique Reagents*
* All ingredients used are of a analytical grade. For aqueous solutions ultrapure water (Milli-Q quality) is used.
1. Tromethamine-NaCl (TN) buffer
Composition of the buffer:
Tromethamine (Tris)
6.057
g (50 mmol)
NaCl
5.844
g (100 mmol)
Water to
1
l
The pH of the solution is adjusted to 7.4 at 37° C. with HCl (10 mmol.l −1 ).
2. TNP buffer
Polyethylene glycol 6000 is dissolved in TN buffer to give a concentration of 3 g.l −1 .
3. S-2222 solution
One vial S-2222 (15 mg; Kabi Diagnostica, Sweden) is dissolved in 10 ml water to give a concentration of 1.5 mg.ml −1 (2 mmol.l −1 ).
4. Xa solution
Bovine Factor Xa Human (71 nKat.vial −1 ; Kabi Diagnostica) is dissolved in 10 ml TNP buffer and then further diluted with 30 ml TNP buffer to give a concentration of 1.77 nKat.ml −1 . The dilution has to be freshly prepared.
Preparation of Test and Reference Compound Solutions
The test and reference compounds are dissolved in Milli-Q water to give stock concentrations of 10 −2 mol.l −1 . Each concentration is stepwise diluted with the vehicle to give concentrations of 10 −3 , 10 −4 and 10 −5 mol.l −1 . The dilutions, including the stock solution, are used in the assay (final concentrations in the reaction mixture: 3·10 −3 ; 10 −3 ; 3·10 −4 ; 10 −4 ; 3·10 −5 ; 10 −5 ; 3·10 −6 and 10 −6 mol.l −1 , respectively).
Procedure
At room temperature 0.075 ml and 0.025 ml test compound or reference compound solutions or vehicle are alternately pipetted into the wells of a microtiter plate and these solutions are diluted with 0.115 ml and 0.0165 ml TNP buffer, respectively. An aliquot of 0.030 ml S-2222 solution is added to each well and the plate is pre-heated and pre-incubated with shaking in an incubator (Amersham) for 10 min. at 37° C. Following pre-incubation the hydrolysis of S-2222 is started by addition of 0.030 ml thrombin solution to each well. The plate is incubated (with shaking for 30 s) at 37° C. Starting after 1 min of incubation, the absorbance of each sample at 405 nm is measured every 2 min for a period of 90 min. using a kinetic microtiter plate reader (Twinreader plus, Flow Laboratories).
All data are collected in an IBM personal computer using LOTUS-MEASURE. For each compound concentration (expressed in mol.l −1 reaction mixture) and for the blank the absorbance is plotted versus the reaction time in min.
Evaluation of responses: For each final concentration the maximum absorbance was calculated from the assay plot. The IC 50 -value (final concentration, expressed in μmol.l −1 , causing 50% inhibition of the maximum absorbance of the blank) was calculated using the logit transformation analysis according to Hafner et al. (Arzneim.-Forsch./Drug Res. 1977; 27(II): 1871-3).
Anti-factor Xa activity
Compound (example)
IC 50 (μg · l −1 )
32 (1)
22
38 (2)
12
56 (3)
12
80 (4)
<2
Abbreviations
(Ph=phenyl; Me=methyl; Ac=acetyl; Im=trichloroacetimidyl; Bn=benzyl; Bz=benzoyl; Mbn=4-methoxybenzyl; Lev=levulinoyl) | The invention relates to a carbohydrate derivative having formula I
wherein R 1 is (1-4C)alkoxy; R 2 , R 3 and R 4 are independently (1-4C)alkoxy or OSO 3 − , the total number of sulfate groups is 4, 5, or 6; and the twisted lines represent bonds either above or below the plane of the six-membered ring to which they are attached; or a pharmaceutically acceptable salt thereof.
The compounds of the invention have antithrombotic activity and may be used for treating or preventing thrombosis and for inhibiting smooth muscle cell proliferation. | 2 |
[0001] This application relates to computer-aided-design systems, and in particular, to methods for detecting and correcting errors arising from such causes as translation of CAD data from one CAD format to another.
BACKGROUND
[0002] A computer-aided design (CAD) system is a tool for creating models of geometric objects on a computer system. These geometric objects, which are typically representative of physical structures, are built by a user using a series of commands that instruct the system to produce primitive entities such as solids, curves, or lines, to define their dimensions, to translate or rotate them through space, and to combine them in a variety of ways.
[0003] A geometric object created by a CAD system is typically represented using a proprietary format that depends on the particular CAD system creating the object. Because the format for an object created by one CAD system is generally different from the format for an object created by another CAD system, it is not possible for one CAD system to operate directly on an object created by another CAD system.
[0004] This inability to freely operate on objects created by a variety of CAD systems is disadvantageous in an environment in which each of several users contributes a particular component or sub-assembly of a larger structure. In such environments, which are increasingly common for the preparation of models of complex systems, different components are created with different CAD systems and integrated into a single heterogeneous assembly of components.
[0005] It is known in the art to provide translation mechanisms to transform a data structure representative of a geometric object in a source format into a corresponding data structure in a target format. It is also known to represent geometric objects in a common format (for example, the IGES format) which is understood by a variety of CAD systems.
[0006] A difficulty that arises, however, is that the translation from a structure represented in a source format into a corresponding structure represented in a target format may not be perfect. As a result, the structure as represented in the target format and the structure as represented in the source format may differ in significant ways. These imperfections can arise from a variety of causes. For example, since a digital computer generally supports only a finite number of significant digits, it is possible that, as a geometric object undergoes translations and rotations, truncation and round-off errors will accumulate. In addition, certain complex geometric entities, such a spline curves, are represented by equations which are themselves approximations of the actual entity. This can result in errors which, although small in the source format, become enlarged during the translation process. Yet another source of imperfection in translation arises from the fact that the tolerances in the source CAD system can be different from the tolerances in the target CAD system. For example, two surfaces considered to be contiguous in the source CAD system may be separated by a gap in a target CAD system.
[0007] These imperfections in the translation from the source format to the target format manifest themselves in a variety of ways. For example, FIG. 1 shows how two surfaces 42 a , 44 a that are contiguous in the source format can emerge, after translation into the target format, as two surfaces 42 b , 44 b slightly displaced relative to each other so that the surfaces are no longer contiguous. FIG. 1 also shows how two vertices 40 a , 43 a sharing the same spatial location in the source format can emerge, after translation into the target format, as two vertices 40 b , 43 b that are slightly displaced relative to each other. In some cases, surfaces that are tangent along their common boundary when represented in the source format are no longer tangent in the target format representation of those two surfaces.
[0008] It is difficult, using conventional surface models of structures, to detect, much less correct, such errors in translation. This is because the target application has no way of knowing that a representation of the structure in the target format is not, in fact, a perfectly accurate representation of the structure as represented in the source format. In effect, because the target application has no context against which to evaluate the integrity of a translation, it has no choice but to accept the translation on faith. As a result of the target applications blind reliance on the integrity of the translation process, it is frequently necessary for designers who import geometric objects from other CAD systems to spend considerable amounts of time making minor changes to the imported structure in order to perfect the translation. The effort associated with this correction process significantly inhibits the free exchange of geometric structures between different CAD systems having different formats for representing geometric objects.
[0009] What is therefore lacking in the art is a method for detecting and correcting such translation errors, thereby facilitating the free exchange of geometric structures created in a variety of CAD systems.
[0010] A related difficulty arises outside the context of translation between a source format and a target format. For example, there are a variety of ways known to generate a surface by applying procedures to other geometric structures. For example, one can generate a surface by interpolating over a set of points in three-dimensional space. Or, one can generate a surface by defining two curves in three-dimensional space and connecting points on one curve with corresponding points on the other curve. However, two surfaces generated in this manner are not guaranteed to be contiguous or to satisfy any other constraint relative to each other. As a result, the two surfaces are quite simple, a designer who creates two such surfaces and seeks to join them together faces a potentially non-trivial task.
[0011] What is therefore also lacking in the art is a method for creating and enforcing constraints between two surfaces.
SUMMARY
[0012] In a method of practicing the invention, an independent basis for verifying the integrity of a translation from a source format representation of a geometric structure to a target format representation of the same structure includes the step of enhancing the target format representation by incorporating into it certain constraints on the constituent elements of the structure that are expected to be satisfied in the source format representation of the geometric structure. The geometric structure generally has a first element, a second element, and a common boundary between the first and second element and the constraint is to be satisfied by the first element at the common boundary.
[0013] To verify the integrity of the translation, the method of practicing the invention includes the step of determining whether or not the constraint is satisfied by the first element in the target format representation of the geometric structure and verifying the integrity of the translation process on the basis of whether the constraint is satisfied by the first element in the target format representation of the geometric structure. This generally includes the step of examining the common boundary between the first and second elements of the geometric structure in the target format to determine if the constraint is satisfied at that boundary.
[0014] Having detected the existence of an error in translation in the foregoing manner, the method of the invention can include the additional step of correcting the translation error by enforcing the constraint at the common boundary between the first and second constituent elements in the target format representation of the geometric structure. This can include the step of altering the target format representation of the structure so as to satisfy the constraints. The step of altering the target format representation to satisfy the constraint at the common boundary can be implemented by perturbing only the first element and constraining the second element to be stationary or by perturbing both the first and second elements.
[0015] The constraints can be generated either interactively, with the user of the data processing system specifying the constraints from an input device, or automatically. The step of automatically generating constraints typically includes the step of applying pre-defined assumptions concerning the geometric structure. These pre-defined assumptions can reflect either prior knowledge of the structure or heuristically derived rules for representation of the structure. Examples of such heuristically defined rules are that elements whose boundaries are separated by a distance small compared to the overall dimension of the structure are expected to be contiguous at those boundaries and that curved elements that share a common boundary are expected to be tangent to each other at the boundary.
[0016] The foregoing method can be used in applications other than the correction of errors associated with translation from a source format to a target format. The method is sufficiently general in its scope to be used to enforce constraints between two constituents of a geometric structure regardless of the origin of the geometric structure. In particular, a user of a CAD system can apply the foregoing method to enforce a constraint between two constituent elements of a geometric object created using that CAD system. This application of the foregoing method can be considered a limiting case in which the source format and the target format are the same format.
[0017] These and other features, aspects, and advantages of the invention will be better understood with reference to the following description and the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 illustrates how, as a result of a translation error, the target format representation of a geometric object can differ from the source format representation of the geometric object;
[0019] [0019]FIG. 2 shows a block diagram of a plurality of CAD systems in communication with a geometry database in a system embodying the principles of the invention;
[0020] [0020]FIG. 3 is a schematic depiction of the geometry editor in one of the CAD systems shown in FIG. 2;
[0021] [0021]FIG. 4 is a flowchart of the steps implemented by the geometry editor of FIG. 3; and
[0022] [0022]FIG. 5A shows a section of a translated object as output by the translator array of FIG. 3 in which components of the structure are displaced as a result of translation errors; and
[0023] [0023]FIG. 5B shows the translated object of FIG. 5A after repairs made by the constraint enforcer of FIG. 3.
DETAILED DESCRIPTION
[0024] Referring to FIG. 2, a data processing system 100 embodying the invention includes a first CAD system 10 a linked to a geometry database 21 of geometric objects. The first CAD system can be a CAD system such as PROENGINEER 2000, available from Parametric Technology of Waltham, Mass.
[0025] The geometry database 21 can be a collection of files on a server or distributed across several servers. Alternatively, the database can be an enterprise-wide data management system such as the WINDCHILL system available from Parametric Technology of Waltham, Mass. The geometry database 21 is linked to a plurality of CAD systems, 10 b - 10 d , all of which can store and retrieve geometric objects in the geometry database 21 . Each of the plurality of CAD systems 10 b - 10 d includes components similar to those described below in connection with the first CAD system 10 a.
[0026] The first CAD system 10 a includes one or more input devices 11 , typically a keyboard operating in conjunction with a mouse or similar pointing device, for communicating instructions from a user to a main processor 14 . The main processor 14 is coupled both to a graphics processor 16 , which can be a separate hardware element or executable software loaded into memory, and to a display terminal 12 .
[0027] The main processor 14 routes those instruction received from the user that are related to the creation and manipulation of geometric objects to the graphics processor 16 and receives instructions from the graphics processor 16 to display appropriate geometric structures on the display terminal 12 . The resulting display on the display terminal 12 provides visual feedback to the user of the first CAD system 10 a.
[0028] The graphics processor 16 is connected to a memory element 18 in which is stored a representation of a geometric object to be operated upon by the graphics processor 16 . There are two ways in which this geometric object can be placed into the memory element 18 . The first way is to create the object directly in the memory element 18 using CAD system commands available for this purpose. The second way is to retrieve the geometric object from the geometry database 21 and place it into the memory element 18 .
[0029] If the geometric object is retrieved from the geometry database 21 , the possibility exists that the object was stored in a format that is not readily understood by the first CAD system. It is therefore necessary to provide a format checker 19 to intercept geometric objects retrieved from the geometry database 21 before they reach the memory element 18 .
[0030] The format checker 19 determines whether the geometric object 201 (hereafter referred to as the retrieved object 201 ) retrieved from the geometry database 21 is of a type that can be understood by the graphics processor 16 . If it is, then no translation is necessary and the retrieved object 201 is placed directly into the memory element 18 . If it is not, the retrieved object 201 must first be passed through a geometry editor 20 before it can be placed into the memory element 18 .
[0031] The geometry editor 20 of the first CAD system 10 a , shown in more detail in FIG. 3, includes a format identifier 22 coupled to a translator array 24 . The format identifier 22 examines the retrieved object 201 and determines which of several available CAD formats the retrieved object 201 is represented in. The format identifier 22 then sends a selection signal 202 encoding this information to a translator array 24 . The translator array 24 then applies an appropriate translator to the retrieved object 201 , thereby generating a translated object 203 .
[0032] The retrieved object 201 is typically stored in a source format that contains only geometric information regarding the object. Such information includes the locations of vertices, curves and surfaces in a coordinate system, or equations defining surfaces and curves. The retrieved object 201 (and hence the translated object 203 ) generally does not include information regarding the desired relationships between particular vertices, curves and surfaces. Of course, if the geometric information is specified exactly and translated with no errors, any desired relationships between the various vertices, curves and surfaces in the translated object 203 will be satisfied. However, the fact that the desired relationships are satisfied is merely a byproduct of having correctly specified the locations of all vertices, curves and surfaces in the retrieved object 201 .
[0033] As an example, consider a model of a boat in which one surface represents the keel and another surface represents the hull. The source format representation of the retrieved object 201 may include an equation for a surface defining the keel and another equation for the surface defining the hull. If these two equations are both chosen correctly, the keel and the hull will intersect and be orthogonal to each other at the locus of points defining their intersection. The source format representation does not, however, include an independent statement of the fact that the keel and hull must intersect orthogonally along a line. This requirement, if satisfied, is satisfied only as a byproduct of the choice of the equations describing the hull and the keel.
[0034] Because the retrieved object 201 , and hence the translated object 203 contains only geometric information regarding the structure, there is no independent basis for assessing the integrity of the translation process. Thus, in the context of the above example, if, upon translation, the model of the boat shows a keel that is almost, but not quite orthogonal to the hull, the CAD system will have no basis for determining whether there has been a translation error, or whether this slight deviation from orthogonality is the result of a deliberate choice made by a designer.
[0035] In a system embodying the invention, an independent basis for evaluating the integrity of the translation process is provided by a constraint generator 32 in communication with the translator array 24 . The constraint generator 32 heuristically determines the constraints imposed on the model by the designer. For example, if the constraint generator 32 observes that, in the translated object 203 , two surfaces are separated by a gap that is very small compared to the overall dimensions of the structure, the constraint generator 32 will assume that an error has been made in translation and that the two surfaces are meant to be joined. The constraint generator 32 then transmits a signal containing constraint information 206 to a model enhancer 34 that incorporates this information into the translated object 203 .
[0036] The model enhancer 34 incorporates the constraint information 206 by generating a hybrid object 204 in which the translated object 203 is augmented by information about relationships that must be satisfied between the various constituents of the structure. These relationships, which are collectively referred to as constraint information 206 , can either be generated heuristically by the constraint generator 32 as described above, or they can be provided directly by the user. The resulting hybrid object 204 thus contains two distinct portions: a geometry portion obtained directly from the translated object 203 output by the translator array 24 and a constraint portion obtained from the constraint generator 32 and combined with the geometry portion by the model enhancer 34 .
[0037] In the preferred embodiment, the constraint information 206 take the form of constraints that are to be satisfied at the boundaries between the various constituents of the structure. Examples of such constraints are: that two surfaces are continuous at their boundary, that two surfaces are tangent at their boundary, or that two surfaces intersect at a specified angle. However, the constraints can be far more complex. For example, one can constrain the center of mass to be located at a certain point, or one can constrain the moment of inertia about a selected axis of the resulting structure be a particular value. The constraint information 206 can be applied to any n−1 manifold boundary of an n manifold object. For example, the constraint generator 32 can impose a constraint at the vertices that form the boundaries of a curve as well as a constraint at the curve forming a boundary between two surfaces.
[0038] Because the hybrid object 204 includes both a constraint portion and geometry portion, an error detector 26 can determine whether the geometry portion and the constraint portion are consistent. The error detector 26 does so by determining whether the structure generated by the geometry portion satisfies the constraints imposed by the constraint portion. The constraint portion thus provides an independent check on the validity and internal self-consistency of the translated object 203 . As a result, the error detector 26 can determine whether or not an error has occurred in generating the translated object 203 from the retrieved object 201 .
[0039] Without the constraint information 206 encoded in the hybrid object 204 , the first CAD system 10 a , when presented, for example, with two surfaces that are very close to being aligned, has no basis for determining whether or not a translation error has occurred or whether the two surfaces are, in fact, supposed to be misaligned. However, if the constraint information 206 encoded into the hybrid object 204 states that the two faces are supposed to be aligned, then the first CAD system 10 a , when faced with the misaligned structures in the translated representation of the structure, has a basis for recognizing that the translation is faulty.
[0040] If it does not detect any errors in the geometric portion of the hybrid object 204 , the error detector 26 routes the hybrid object 204 directly to the output of the geometry editor 20 where it is made available for loading into the memory element 18 . If, on the other hand, the error detector 26 detects that one or more constraints specified in the constraint portion of the hybrid object 204 are not satisfied in the geometry portion, the hybrid object 204 is first passed to a repair module 36 before being made available to the memory element.
[0041] The constraint enforcement module 36 repairs the hybrid object 204 by adjusting the geometry portion of the hybrid object 204 so as to satisfy the constraints specified in the constraint portion of the hybrid object 204 . This process typically includes perturbation of one or more constituents of the geometric object in an effort to satisfy the constraints. In some cases, the constraint may impose limitations on the amount by which a particular constituent of the geometric object may be perturbed. For example, a constraint may specify that two structures are to be contiguous but that in the event they are not contiguous, one of the two surfaces must remain stationary.
[0042] The output of the constraint enforcement module 36 is a repaired hybrid object 208 which becomes the output of the geometry editor 20 . This output is then made available to the memory element 18 where it can be operated upon by the graphics processor 16 of the first CAD system 10 a.
[0043] [0043]FIG. 4 shows a flowchart illustrating the steps used to verify the integrity of the translation from the source format to the target format and to repair the target format so that it is consistent with the source format. The method 400 begins with the step 401 of retrieving an object from the geometry database and determining 411 whether the retrieved object is in a format that can be understood by the CAD system. If it is, then the retrieved object is routed 444 directly to the memory element. If it is not, then the retrieved object is passed to the geometry editor.
[0044] Once the retrieved object is passed to the geometry editor, its format is identified 422 and translated from that format into a translated object format that can be understood by the CAD system. Meanwhile, any constraints associated with the structure are generated 432 and incorporated 434 into the translated object, thereby generating a hybrid object having a geometry portion and a constraint portion.
[0045] The next step in the method of the invention is to determine 426 whether there has been an error in translation. This is done by determining whether the generated constraints in the constraint portion of the hybrid object are satisfied by the geometry portion of that object. If they are, then output of the geometry editor is set 442 to be the translated model. Otherwise, the translated object is repaired by enforcing 436 the constraints generated in step 432 of the illustrated method 400 . The repair, or constraint enforcement process generally includes the step of perturbing the constituents of the geometric object represented by the geometric portion of the hybrid object so as to satisfy the constraints. After undergoing repairs in this manner, the hybrid object (now referred to as the “repaired object”) is set 440 to be the output of the geometry editor.
[0046] An example of the type of perturbation performed by the constraint enforcer 36 is illustrated in FIGS. 5A and 5B. FIG. 5A shows, in cross-section, a translated object 203 that includes a section of a parabolic cylinder 46 and a plane 47 a . In the translated object 203 , the cross-section of the parabolic cylinder 46 is defined by the equation
y=x 2 (1)
[0047] and the cross-section of the plane 47 a is defined by the equation
y =(2.001 x 0 ) x− 1.001 x 0 2 (2)
[0048] As a result, the plane 47 a and the parabolic cylinder 46 are neither continuous nor tangential along their boundaries.
[0049] A user observing this apparent translation error can instruct the constraint generator 32 to generate three constraints to be satisfied by the parabolic cylinder 46 and the plane 47 a along their boundaries: that they are contiguous, that they are tangential, and that the parabolic cylinder 46 be held stationary. These constraints can be provided interactively by the user, as described above, or they can be generated automatically by heuristic rules. Whichever way they are generated, the model enhancer 34 incorporates them into the translated object 203 , thereby generating a hybrid object 204 having a geometry portion and a constraint portion.
[0050] When the hybrid object 204 is passed to the error detector 26 , the error detector 26 recognizes that the constraint portion of the hybrid object 204 is inconsistent with the geometry portion of that object. In response, the error detector 26 passes the hybrid object 204 to the constraint enforcer 36 for repairs consistent with the constraint portion of the hybrid object 204 .
[0051] The repaired hybrid object 208 generated by the constraint enforcer is shown in FIG. 5B. Because of the constraint that the parabolic cylinder 46 is to be held stationary, the constraint enforcer leaves equation (1) for the parabolic cylinder 46 unchanged. Because of the constraint that the two surfaces must be contiguous along their boundary, the constraint enforcer perturbs the y-intercept of equation (2) so that the plane 47 a and the cylinder 46 meet along their boundary. Finally, because of the constraint that the two surfaces must be tangential to each other along their boundary, the constraint enforcer perturbs the slope of equation (2) so that it matches the first derivative of equation (1) along the line defining the intersection of the parabolic cylinder 46 and the plane 47 a . The resulting representation of the plane 47 b in the repaired hybrid object 208 is thus:
y =(2 x o ) x−x 0 2 (3)
[0052] The resulting representation of the plane 47 b and the parabolic cylinder 46 satisfies all the constraints imposed by the constraint generator 32 and presumably undoes any errors associated with the translation process. | A method for determining the existence of an error in translating from a source format of a geometric object to the corresponding target format and correcting that error includes the step of specifying constraints to be satisfied by the constituents of the geometric object and augmenting the target format representation of the object with those constraints. The resulting target representation thus includes both geometric and constraint information. The validity of the translation is assessed by determining whether or not the geometric portion is consistent with the constraint portion. If it is not consistent, the constraint information is then used to correct the translation errors. The constraints are either specified by a user, known beforehand, or heuristically determined. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates in general to sensors located on a vehicle used to detect obstructions.
BACKGROUND OF THE INVENTION
[0002] Vehicles with reverse sensing systems use one or more sensors on the rear bumper of the vehicle to sense obstacles to the rear of the vehicle while it is backing up. The sensors typically alert the driver through audible and/or visible indicators. In general, a reverse sensing system is only enabled when the vehicle gear select lever is in the “reverse” position.
[0003] Some vehicles are equipped with a power liftgate actuator system. In such systems, the liftgate is driven to the open position at the touch of a button. Vehicles with this system are at a risk of the liftgate colliding with outside obstacles and causing vehicle damage during the opening movement if the operator is not diligent at assuring that the liftgate path is clear of obstacles. Some software algorithms used to control the liftgate have sensing to react when an obstruction is encountered, then reverse or discontinue the drive power to the liftgate. This method does not prevent the damage from occurring, but only reacts after impact, thereby failing to eliminate the risk of vehicle damage.
[0004] What is needed is the ability to sense obstacles in the path of the liftgate prior to any contact with the liftgate and to automatically stop the opening movement of the liftgate when an obstacle is detected. Ideally, such a system should be integrated with the rear obstacle detector system.
SUMMARY OF THE INVENTION
[0005] The present invention employs the sensors used for sensing objects when a vehicle is in reverse to also prevent vehicle damage when the power liftgate is activated. Specifically, the method for sensing an obstruction to the rear of a vehicle comprises the steps of disposing at least one sensor in the liftgate and generating a first signal when the sensor indicates an obstruction when the liftgate is opening. In another aspect of the invention, the method further comprises the step of generating a second signal when the sensor indicates an obstruction when the vehicle is reversing.
[0006] The apparatus of the present invention comprises at least one sensor disposed in the liftgate and means for generating a first signal when the sensor indicates an obstruction when the liftgate is opening. In another aspect of the invention, the apparatus further comprises means for generating a second signal when the sensor indicates an obstruction when the vehicle is reversing.
[0007] Preferably, the first signal sent from the controller when the sensor indicates an obstruction in the liftgate path could be either an audible and/or a visible alarm, or it could be a signal stopping or reversing the liftgate driver, typically a motor. The second signal sent from the controller when the sensor indicates and obstruction to the rear of the vehicle while it is reversing could be either an audible and/or a visible alarm.
[0008] In one aspect of the invention, the system disables the power liftgate driver when the vehicle is not in park.
[0009] Thus, the present invention, by locating the sensor or sensors at one or more locations on the liftgate, allows the sensors to remain functional as detectors for obstacles when the vehicle is reversing, continuing to activate appropriate warnings for the vehicle operator. Further, when the power liftgate is deployed, the sensor or sensors act as anticipators to prevent liftgate collisions with outside obstructions by stopping or reversing the liftgate or warning the vehicle operator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The various features, advantages, and other uses of the present invention will become more apparent by referring to the following detailed description and drawings in which:
[0011] [0011]FIG. 1A is a pictorial diagram of a vehicle with a liftgate, which vehicle incorporates the present invention;
[0012] [0012]FIG. 1B is the rear view of the vehicle of FIG. 1A;
[0013] [0013]FIG. 2 is a data flow diagram of vehicle control components involved in carrying out the present invention; and
[0014] [0014]FIG. 3 is a flow diagram illustrating the method according to the present invention.
DETAILED DESCRIPTION
[0015] Referring to FIGS. 1A and 1B, shown is a vehicle incorporating the present invention. The vehicle 10 includes a power liftgate 12 and a bumper 14 . Disposed in the liftgate 12 is at least one sensor 16 located toward the bottom edge of the liftgate 12 near the bumper 14 . In one aspect of the invention, one sensor 16 is disposed in the center of the liftgate 12 . In another aspect of the invention, two sensors 16 are disposed in opposite corners of the liftgate 12 on the same horizontal plane. Although the invention is shown incorporating either one or two sensors 16 , more than two sensors could be used. The number of sensors used is dependent on the field of view of the sensors. The sensors 16 should be placed so that their fields of view overlap and/or cover the entire length of the bumper 14 from end to end. Additional sensors could be located on the bumper 14 to perform sensing when the vehicle is reversing.
[0016] The sensors 16 are common sensors used for electronically sensing objects in the path of the sensors, which would indicate an obstruction to the vehicle on which the sensor is mounted. Such sensors 16 may be ultrasonic, charge coupled device (CCD) camera, radar, etc. A typical sensor includes a transceiver that transmits signals and subsequently receives signals reflected from an object in the sensor path. The reflected signals are emitted as a signal to a processor coupled to the transceiver, where the processor analyzes the received signal to detect the presence, and often the distance, of an obstruction. A conventional ultrasonic sensor typically emits ultrasonic waves utilizing the resonance phenomena exhibited by an ultrasonic resonator, and the resonator receives reflected waves from an object, which waves are analyzed by the processor. Similarly, a CCD camera emits light according to a predetermined wavelength and receives a reflection of that light for analysis. The radar sensor generally operates using transmission of a frequency modulated carrier signal. An example of a vehicle exterior object sensor is described in U.S. Pat. No. 5,844,471, which is incorporated herein by reference.
[0017] Referring now to FIG. 2, the engine controller 62 receives an indication of gear position. The controller 62 may be a conventional microcontroller which includes such elements as a central processing unit (CPU), read only memory, random access memory, input/output control circuitry, and analog to digital conversion circuitry. The controller 62 is activated upon application of ignition power to an engine. When activated, the controller 62 carries out a series of operations stored in an instruction-by-instruction format in memory for providing engine control, diagnostic and maintenance operations. Preferably, the transmission 60 of the vehicle provides the indication of gear position to the controller 62 . Alternatively, the vehicle gear select lever provides the gear indication.
[0018] The sensors 16 provide signals 64 to the controller 62 indicating the presence of an object in the path of each sensor. The controller 62 receives and analyzes the signals 64 to determine whether an obstruction is present, requiring an actuator signal to a liftgate driver 66 , usually a motor, or a signal to an automobile warning system 68 or both.
[0019] [0019]FIG. 3 shows how the sensors 16 are used to perform reverse sensing and liftgate damage avoidance according to the method of the present invention. The procedure starts at step 20 upon initialization of power to an engine controller 62 . Then, the procedure makes a query as to whether the vehicle ignition is “on” or not in step 21 . If the vehicle ignition is “on,” the procedure advances to step 22 , where a query is made as to whether the vehicle is in park. If the vehicle is in park, the procedure advances to step 24 . At step 24 , a query is made as to whether the power liftgate 12 is active, which means that the liftgate driver 66 is energized. If the liftgate 12 is not active, then the procedure returns to step 22 . If, however, the liftgate 12 is active, the procedure advances to step 26 .
[0020] Returning now to step 21 , if the vehicle ignition is not “on,” the procedure advances directly to step 24 to determine whether the power liftgate 12 has been activated.
[0021] Powered systems for opening and closing a vehicle liftgate are known in the art. Generally, such systems comprise a pair of drive units attached to the vehicle frame and connected to the liftgate. Each drive unit includes a bracket secured to the vehicle body, supporting several parts including a reversible electric driver, usually a motor, a gear train, a rack and a cradle mounted on the bracket. The electric driver drives the rack from a retracted position to an extended position and back via an output gear with an axis. The rack slides in the cradle, which cradle is pivotally mounted on the bracket so that the cradle pivots about the axis of the output gear to hold the teeth of the rack in engagement with the teeth of the output gear. The electric driver is controlled via electric motor controls, well known to those skilled in the art.
[0022] In step 26 , the liftgate sensing system is enabled when the power liftgate is activated. The procedure then advances to step 28 , where a query is made as to whether an obstruction has been detected by the sensors 16 . If an obstruction has not been detected, i.e., an object is not within the range of view of a sensor 16 , the sensors 16 continue to be monitored until the liftgate 12 is no longer activated, shown in step 30 . If the liftgate 12 is activated, then the procedure returns to step 28 to determine if an obstruction is detected. If the liftgate 12 is no longer activated, then the procedure advances to step 32 , where the liftgate sensing system is disabled. The procedure then ends at step 34 .
[0023] Returning now to step 28 , if an obstruction is detected by the sensors 16 , then the procedure advances to step 36 , where the operation of the liftgate is halted or reversed by an actuator signal provided to the electric driver 66 of the power liftgate actuator system. In one aspect of the invention, in addition to halting or reversing the operation of the liftgate, a warning could be transmitted to the driver, similar to the warning provided to the driver when an obstruction is detected by the reverse sensing system. The procedure advances to step 32 , where the liftgate sensing system is disabled. Then, the procedure ends at step 34 .
[0024] Returning now to step 22 , if the vehicle is not in park, the procedure advances to step 38 , where the power liftgate driver 66 is disabled. Next, a query is made in step 40 as to whether the vehicle is in reverse. If the vehicle is not in reverse, the procedure ends at step 34 . If the vehicle is in reverse, then the procedure advances to step 42 . In step 42 , the reverse sensing system is enabled. In step 44 , the query is made as to whether the sensors 16 have detected an obstruction. If an obstruction has not been detected in step 44 , the procedure advances to step 46 where a query is made as to whether the vehicle is still in reverse. If the vehicle is still in reverse, the procedure returns to step 44 to check the sensors 16 for detected objects. If, however, the vehicle is no longer in reverse, then the procedure advances to step 48 where the reverse sensing system is disabled. The procedure then ends at step 34 .
[0025] Returning now to step 44 , if an obstruction is detected by the sensors 16 , the procedure advances to step 50 , where a warning is sent to the driver. The warning can be a visual and/or an audible alarm, conventional in the art. An audible alarm is generally a solid state piezoelectric alarm, while a visual alarm generally comprises a lamp or lamps lit or flashing when an obstruction is detected. Generally, the audible alarm sounds a warning of an obstruction that beeps faster and/or at a higher pitch as the vehicle approaches the obstruction. Similarly, the closer the obstruction is to a vehicle equipped with a visual alarm, the increasingly bright the lamp, or the faster the lamp flashes. After the warning is sent, the procedure returns to step 46 where a query is made as to whether the vehicle is in reverse. If the vehicle is still in reverse, the procedure returns to step 44 to check the sensors 16 for detected obstructions. If, however, the vehicle is no longer in reverse in step 46 , the reverse sensing system is disabled in step 48 . The procedure then ends at step 34 .
[0026] The procedure runs continuously at predetermined intervals while engine power is on. When the engine is off, the procedure is performed when the liftgate 12 is activated.
[0027] The method and apparatus of the present invention provides a vehicle with a unique system that provides detection of obstructions while the vehicle is reversing, and also provides a sensing system to avoid liftgate damage. The invention uses the same sensors to perform both functions. | The present invention is a method and apparatus of performing vehicle obstruction sensing during vehicle reverse and liftgate opening movements. The invention uses the same sensors to perform both functions. When the vehicle is in reverse, the invention produces a visible and/or audible signal to the operator of the vehicle when an obstruction detected within the monitoring range of the sensor or sensors. When the vehicle transmission is in any position other than park, the liftgate driver is disabled. When the vehicle is in park, the liftgate sensing system is enabled. The invention either stops the liftgate opening movement or reverses the liftgate movement when an obstruction is detected. The invention can also signal an alarm when an obstruction is detected in the path of the liftgate. The present invention incorporates any number of existing sensors. | 4 |
BACKGROUND OF THE INVENTION
[0001] This application is related to U.S. application titled, “METHOD AND APPARATUS FOR MANUFACTURING WALLPAPER WITH ERASABLE FRONT MATCH MARKS,” which was filed on even date herewith; attorney docket number 2380.1 and inventor Patrick J. Bluett.
FIELD OF THE INVENTION
[0002] This invention relates to the field of positioning wallpaper and more particularly to matching two abutting sheets of wallpaper.
DESCRIPTION OF THE RELATED ART
[0003] Wallpaper is applied to a surface such as a wall in wide varieties of ways. Typically, wallpaper is applied to the entire wall surface and often to all or most of the wall surfaces in a room.
[0004] Wallpaper is typically provided in rolls. Sheets of the approximate height of the wall are cut, water is applied to pre-pasted wallpaper or adhesive applied to un-pre-pasted wallpaper and the sheet is placed on the wall, adhesive side down, each sheet next to the previous sheet until the desired area is covered.
[0005] Wallpaper comes in a wide variety of designs and patterns. As an example, one such wallpaper has a paisley pattern, having designs of paisley interspersed regularly across its surface. When two strips of wallpaper are to be placed next to each other, an aesthetic or other acceptable match of the two pieces of wallpaper can be obtained if the pattern on the wallpaper is subtle e.g. does not have a large dominant feature. However if the wallpaper does have a dominant feature such as the paisley pattern, it is preferable that the abutting sheets of the wallpaper are abutted such that the pattern flows across the entire wall and/or room.
[0006] Typically, a pattern on wallpaper repeats at fixed intervals such as every two feet. To align such wallpaper, often a reference line is printed on each side of the back surface of the wallpaper. To successfully align the pattern, the right reference line of the first sheet needs to line up with the left reference line of the sheet to its right, and so forth. Unfortunately, once the first sheet is hung, it is difficult to find the location of the reference line being that the reference line is against the wall. Often, the wallpaper hanger will mark the wall with a pencil next to the location of the reference mark. That withstanding, when hanging the second sheet, it is difficult to find and see the pencil mark since it is covered by the second sheet and it is difficult to see/find the reference mark on the second sheet since it is on the adhesive side of the wallpaper.
[0007] U.S. Pat. No. 6,024,821 to Cousineau describes a method of matching wallpaper borders using a clear plastic sheet. This method requires extra tools and is not described for matching wallpaper, only borders.
[0008] What is needed is a wallpaper matching and alignment system that will improve the ease at which wallpaper with patterns is hung.
SUMMARY OF THE INVENTION
[0009] In one embodiment, wallpaper with match marks is disclosed including a continuous sheet of wallpaper having a front surface, a back surface, a left edge and a right edge and a decorative pattern printed on the front surface. A plurality of erasable left match marks are spaced along the left edge of the front surface and a plurality of erasable right match marks spaced along the right edge of the front surface.
[0010] In another embodiment, a method of hanging wallpaper is disclosed including (1) providing wallpaper with match marks, the wallpaper is a continuous sheet with a front surface, a back surface, a left edge and a right edge and has a decorative pattern printed on its front surface. The wallpaper also has a plurality of erasable left match marks spaced along the left edge of the front surface and a plurality of erasable right match marks spaced along the right edge of the front surface. The method continues with (2) either applying water (for pre-pasted wallpaper) or applying paste to the back surface of a first sheet of the wallpaper and (3) hanging the first sheet of wallpaper vertically on a wall. Next, (4) paste is applied to the back surface of a next sheet of the wallpaper and (5) the next sheet of wallpaper is hung vertically on the wall, aligning the right match marks of the first sheet of wallpaper with the left match marks of the next sheet of wallpaper. (6) If more sheets of wallpaper need be hung, steps 4 and 5 are repeated. After each sheet of wallpaper is hung or when the job is completed, (7) the left match marks and the right match marks are erased using a moist instrument such as a sponge.
[0011] In another embodiment, wallpaper is disclosed including a continuous sheet of wallpaper having a front surface, a back surface, a left edge and a right edge with a decorative pattern printed on the front surface. A first part of a scheme for aligning multiple sheets of the wallpaper is spaced along the left edge of the front surface and a second part of a scheme for aligning multiple sheets of the wallpaper spaced along the right edge of the front surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
[0013] FIG. 1 illustrates a schematic view of a match marking system of the present invention.
[0014] FIG. 2 illustrates a schematic view of a match marking system of the present invention after the match marks have been removed.
[0015] FIG. 3 illustrates an isometric view of a roll of wallpaper of the present invention showing the match marks.
[0016] FIG. 4 illustrates a typical printing device of the present invention for printing the match marks.
[0017] FIG. 5 illustrates a plan view of a typical wallpaper printing operation of the present invention.
[0018] FIG. 6 illustrates a flow chart of a method of hanging wallpaper using the match marks of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
[0020] Referring to FIG. 1 , a schematic view of a match marking system of the present invention will be described. In this typical wallpaper with a pattern 16 , it can be seen that the pattern 16 repeats, in that in each successive sheet of wallpaper 5 / 6 / 7 / 8 . To achieve a desired level of aesthetic appeal, it is important that the patterns of each successive sheet 5 / 6 / 7 / 8 align with the previous sheet 5 / 6 / 7 / 8 so that the pattern continues across the entire covered surface. For example, in the simple pattern shown, the sail boats 16 align on a slight downward angle to the right. In other words, a sail boat 16 in the second sheet 6 is slightly lower than its corresponding sail boat 16 of the previous sheet (left) 5 and that follow through to the next sheet where a sail boat 16 in the third sheet 7 is slightly lower than its corresponding sail boat 16 of the second sheet 6 , and so forth. In this way, the pattern runs across the entire surface or wall. Without a method of aligning the sheets of wallpaper 5 / 6 / 7 / 8 , the pattern (sail boats 16 ) would be random and would not be aesthetically pleasing when viewed at a distance.
[0021] To achieve this alignment, match marks 12 / 13 / 14 / 15 are printed on the face of the wallpaper. When hanging the wallpaper 5 / 6 / 7 / 8 , a paper hanger will typically start by applying a first sheet to the surface (wall) using wallpaper paste (note, some wallpaper is pre-pasted and need only be wet to activate the paste). The first sheet 5 is hung vertically on the wall and a second sheet 6 is prepared and hung to the right of the first sheet 5 . In order to assure correct pattern matching, the right edge match marks 12 of the first sheet 5 is aligned with the left edge match marks 14 of the second sheet 6 . Although the match marks 12 / 13 / 14 / 15 are shown with arrows 12 / 14 and words POINT 15 and MATCH 13 , any marking is envisioned that provides for alignment of one sheet to a subsequent sheet of wallpaper.
[0022] Once the wallpaper 5 / 6 / 7 / 8 is hung and aligned correctly, there is no further need for the match marks 12 / 13 / 14 / 15 . Actually, the finished wall would not look good if the match marks 12 / 13 / 14 / 15 remained. Therefore, it is important that the match marks 12 / 13 / 14 / 15 be easily removable, preferably with a soft, wet cloth, sponge or the like. This is achieved through the use of inks that do not permeate into the wallpaper and are erasable when wetted with water.
[0023] Referring to FIG. 2 , a schematic view of a match marking system of the present invention after the match marks have been removed will be described. The sheets of wallpaper 5 / 6 / 7 / 8 are correctly hung and the patterns 16 flow correctly across the multiple sheets 5 / 6 / 7 / 8 . In FIG. 2 , there are no match marks remaining. The match marks 12 / 13 / 14 / 15 as shown in FIG. 1 were removed using a moistened instrument such as a wash cloth, rag, sponge, etc. It is preferred that the ink used to print the match marks be capable of being erased with minimal friction using water and such an instrument. It is also preferred that the ink be such that the ink dies not sublimate into the wallpaper, especially on very porous wallpaper surfaces.
[0024] Referring to FIG. 3 , an isometric view of a roll of wallpaper of the present invention showing the match marks will be described. Wallpaper 10 is normally provided on rolls as shown in FIG. 3 . The wallpaper 10 of the present invention has match marks 12 / 13 / 14 / 15 for example, the left side arrow 12 that matches with the right side arrow 14 . In some embodiments, words 13 / 15 are printed above or below the arrows 12 / 14 to call attention to the arrows 12 / 14 , for example, “MATCH” 13 and “POINT” 15 . Many other match markings are possible in various shapes, styles, sizes and wording, all of which are included in the present invention.
[0025] Referring to FIG. 4 , a typical printing device of the present invention for printing the match marks will be described. The wallpaper printing device 30 has an input roller 50 for accepting a continuous sheet of wallpaper from previous printing devices (see FIG. 6 ). In some embodiments, the input roller 50 contains a chiller roller as known in the industry for cooling the wallpaper before it enters the print rollers 32 / 54 . The wallpaper is guided by guide rollers 52 to the actual print mechanism that comprises a print cylinder 32 with the pattern (e.g., match marks 12 / 13 / 14 / 15 ) and a pressure roller 54 that provides pressure to the wallpaper so it can accept the pattern from the print cylinder 32 . The print cylinder 32 picks up ink from an ink tray 34 as it rotates. In some embodiments, a doctor blade (not shown) wipes off excess ink before the print cylinder 32 rotates beneath the wallpaper. The wallpaper with the printed match marks 12 / 13 / 14 / 15 then passes over additional guide rollers 52 through a heating area 56 to dry the inks and finally, the wallpaper passes around an output roller 58 to the roll processing area where it is rolled, cut and packaged. In some embodiments, the output roller 58 contains a chiller roller as known in the industry for cooling the wallpaper before it enters the roll processing area.
[0026] The ink used to print the match marks 12 / 13 / 14 / 15 needs to be kept at a low temperature so it does not coagulate in the ink tray 34 or on the rollers. One such ink is “Aqua Safe Removable Ink” number 7.2377 from Polytex Environmental Inks, 820 East 140th Street Bronx, N.Y. 10454. To keep the ink at a low temperature, the ink is constantly cycled from a reservoir 37 through the ink tray 34 and back to the reservoir 37 by a pump 36 . The ink in the reservoir 37 is cooled by refrigeration coils 39 that are fluidly interfaced with a refrigeration unit 38 as known in the industry. In the preferred embodiment, the refrigeration coils 39 are immersed in the ink in the reservoir 37 (as shown). In alternate embodiments, the refrigeration coils 39 are disposed around the perimeter of the reservoir 37 or as known in the industry. Other methods of cooling the ink are known in the industry and included here within.
[0027] Referring to FIG. 5 , a plan view of a typical wallpaper printing operation of the present invention will be described. A continuous feed of blank wallpaper enters a first printing device 70 and is printed with a first pattern 72 as known in the industry. After passing through the drier of the printing device 50 , the continuous sheet of wallpaper exits the first printing device 70 and enters the second printing device 60 and is printed with a second pattern 62 as known in the industry. It is well known how to print different sections or colors of a pattern using different print cylinders (e.g., the first print cylinder 72 and second print cylinder 62 ) with different color inks, etc. It is anticipated that, depending upon the pattern and number of colors, several printing devices 60 / 70 are used. This is well known in the industry. Although the match mark 12 / 13 / 14 / 15 is preferably printed on the face of the wallpaper by the print mechanism 30 after the pattern is printed, in alternate embodiments, it is printed before the pattern or in between other print steps.
[0028] In the example shown, the final print stage is a print device 30 for printing the match mark 12 / 13 / 14 / 15 . This stage uses the ink cooling mechanism as described above consisting of the ink tray 34 fluidly coupled to the ink reservoir 37 by a pump 36 . The ink in the reservoir 37 is cooled by coiling tubes/coil 39 that is/are fluidly coupled to a refrigeration unit 38 .
[0029] Referring to FIG. 6 , a flow chart of a method of hanging wallpaper using the match marks of the present invention will be described. The described process for hanging wallpaper using the match marks of the present invention is abbreviated for clarity. Those skilled in the art will realize that hanging wallpaper requires cutting the sheets to the approximate height of the walls, if needed, trimming the sheets, making sure the sheets are applied vertically using a plumb bob, etc., and after the paper is hung, trimming and smoothing the paper. These steps are well known in the industry and are omitted to clearly describe the present invention. Also, some wallpaper is pre-pasted and, instead of applying paste as in steps 132 and 136 , the paste on the backing of the wallpaper is moistened with water.
[0030] Hanging 130 begins with applying water or paste to a sheet of wallpaper 132 (the wallpaper is cut slightly longer than the height of the wall). Next, the sheet is placed vertically on the wall 134 (a plumb line is often used to assure a vertical hanging). Paste or water is then applied to the next sheet 136 and it is placed on the wall next to the previous sheet such that the match marks on the face of the right side of the first (previous) sheet align with the match marks on the face of the left side of the next sheet 138 . If more sheets of wallpaper need to be hung 140 , the previous two steps 136 / 138 are repeated until the wall is covered. Once finished hanging the wallpaper, the match marks on the face of the wallpaper are removed using a moistened cloth, sponge or other instrument and a slight rubbing motion 142 and the job is finished 144 .
[0031] Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
[0032] It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | An application for wallpaper with match marks includes a continuous sheet of wallpaper having a front surface, a back surface, a left edge and a right edge and a decorative pattern printed on the front surface. A plurality of erasable left match marks are spaced along the left edge of the front surface and a plurality of erasable right match marks spaced along the right edge of the front surface. | 3 |
BRIEF SUMMARY OF THE INVENTION
There is described herein with reference to the accompanying drawings a radiation dosimeter assembly typically mounted within a cup-like enclosure for uranium exploration applications, wherein a thin thermoluminescent radiation dosimeter is intimately disposed on the surface of a metal support member which exhibits sufficient mechanical strength to serve as a support member for the dosimeter and exhibits high electrical resistance characteristics which will permit it to function as the heating element during the readout process of the radiation dosimeter. A preferred embodiment consists of a Nichrome support member and a thin film of a thermoluminescent phosphor/binder composition disposed in intimate contact with a surface of the Nichrome support member.
In the readout process electrical current is passed through the Nichrome support member resulting in the heating of the Nichrome support member and the thermoluminescent dosimeter to a temperature of about 300° C. At this temperature the thermoluminescent phosphor material of the radiation dosimeter will emit light in proportion to the amount of radiation stored in the dosimeter.
An alternate radiation dosimeter assembly consists of a thin film thermoluminescent radiation dosimeter disposed in intimate contact with a Teflon support member. This dosimeter is contrasted with the conventional radiation monitoring badge used by personnel working within potentially dangerous nuclear radiation environments. The conventional badge is composed of a homogeneous mixture of a suitable phosphor material and binder to form cards having dimensions of approximately 32 mm×45 mm×0.4 mm. The thickness of the conventional card or badge renders it ineffective as an alpha responsive radiation dosimeter of the type described and illustrated in U.S. Pat. No. 4,053,772, titled LOCATING UNDERGROUND URANIUM DEPOSITS, assigned to the assignee of the present and incorporated herein by reference. This patent teaches the technique of monitoring radiation on the basis of alpha particles, and teaches that successful monitoring of alpha particles requires a thermoluminescent dosimeter/binder composition in a range of between approximately 1 and 3 mils in thickness. The patent discloses the preferred thermoluminescent phosphor/binder composition to consist of calcium sulfate:dysprosium as the thermoluminescent phosphor and Teflon as the binder. Thus, the successful application of the teachings of this patent to a personnel radiation monitoring badge is realized when an alpha sensitive radiation dosimeter composition of a thickness between approximately 1 and 3 mils is disposed in intimate contact with a surface of a Teflon support member wherein the combination corresponds in dimension to the above dimension of the conventional radiation monitoring badge. By conforming the dimensions of the newly disclosed alpha sensitive personnel radiation monitoring badge to the dimensions of the conventional radiation monitoring badge, the reading of the new alpha sensitive personnel radiation monitoring badge can be achieved through the use of the readout equipment designed for the above-identified conventional radiation monitoring badge.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional schematic illustration of an improved radiation dosimeter/support assembly secured within a typical cup-like enclosure used for uranium exploration;
FIG. 2 is a top view of the radiation dosimeter/support assembly of FIG. 1;
FIG. 3 is a sectional illustration of an alternate radiation dosimeter/assembly; and
FIG. 4 is a top view of the assembly of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Thermoluminescent radiation dosimeters, sensitive to radon emanating from the earth, have found widespread use in uranium exploration applications. Typically, a thin, i.e., 1 to 3 mils, wafer-like radiation dosimeter is supported on a mechanical bracket within a cup-like member which is buried in an inverted position beneath the surface of the ground for a period of weeks. The radiation dosimeter is exposed to radiation emanating from the ground and develops a stored radiation dosage indicative of radon gas. The radiation dosimeter is temporarily secured to the mechanical bracket for installation in the cup-like enclosure. Following several weeks of exposure to radiation emanating from the earth, the radiation dosimeter is removed from the mechanical bracket and secured to a heating element in a radiation dosimeter readout apparatus. The thermoluminescent phosphor comprising the thermoluminescent radiation dosimeter responds to heating to a temperature of approximately 300° C. by emitting light which is indicative of the stored radiation. Following the readout process, the radiation dosimeter is removed from the heating element and is once again available for mechanical attachment to the support bracket of the cup-like enclosure.
Typical thermoluminescent radiation dosimeters are described in issued U.S. Pat. Nos. 3,883,748 and 3,471,699. A conventional readout process for the radiation dosimeter is described in U.S. Pat. No. 3,300,643. Illustrations of the positioning of the radiation dosimeter within a cup-like enclosure for subsurface uranium exploration can be found in U.S. Pat. Nos. 4,064,436 and 4,065,972.
An improved subsurface radiation dosimeter for uranium detection based on the sensitivity of the dosimeter to alpha particles is described in U.S. Pat. No. 4,053,772, issued Oct. 11, 1977, assigned to the assignee of the present invention and incorporated herein by reference.
An improved technique for handling the radiation dosimeter during the readout process to minimize physical deterioration of the dosimeter is described in pending U.S. patent application Ser. No. 928,641, filed July 27, 1978, titled IMPROVED HEATER DESIGN FOR READING RADIATION DOSIMETERS, and assigned to the assignee of the present invention.
Referring to FIG. 1, there is illustrated a cup-like radiation measuring apparatus 10 comprising an inverted cup-like enclosure 12 having an open end and a closed end, and a radiation dosimeter/support member assembly 20 secured within the cup-like enclosure 12 by spring clips 30 attached to the inside walls of the cup-like enclosure 12. The spring clips 30 allow for easy insertion and removal of the radiation dosimeter/support member assembly 20.
As contrasted with the prior art conventional techniques, wherein the radiation dosimeter and the mechanical support member are independent elements allowing for the attachment and removal of the dosimeter from the support bracket to permit removal of the radiation dosimeter element from the support bracket for the purposes of radiation readout, the radiation dosimeter/support member assembly 20 is single, integral combination of a radiation dosimeter 22 and a support member 24.
Unlike the prior art approach wherein the support members sole function was to provide a mechanical element for retaining the dosimeter within the cup-like enclosure, the support member 24 is constructed of a material which will not only provide the desired mechanical support, but exhibits high electrical resistivity such that the support member also functions as the heating element in the readout process for the radiation dosimeter 22. A particularly suitable material for implementing the support member 24 is Nichrome. Thus, the thermoluminescent radiation dosimeter 22 is integrally bonded or intimately secured to a surface of the support member 24 which more accurately can be referred to as a heater/support member, and the combination forming the radiation dosimeter/support member 20 forms a single integral unit which is inserted within the cup member 12 for the purposes of monitoring radiation, and is subsequently removed as a unit and positioned within a conventional readout apparatus for reading the light emitted by the dosimeter 22 in response to dosimeter heating provided by the support member 24 in response to electrical current flow through the support member 24.
Referring to FIG. 2, the radiation dosimeter 22 covers a central portion of the support member 24, allowing end portions 25 and 27 free of the radiation dosimeter 22 and available for electrical connection to the heater power supply 40. The current flow through the support member 24 produced by the heater power supply 40 establishes the support member 24 as a dosimeter heating element to affect the necessary heating of the radiation dosimeter in accordance with the conventional radiation dosimeter readout process. The intimate bonding of the radiation dosimeter 22 to a surface of the support member 24 can be achieved through several techniques, including the use of bonding or adhesive material such as polyimide.
Yet another technique which was found to be effective through detailed experimentation consists of the formulation of an emulsion of a desired thermoluminescent phosphor, i.e., CaSO 4 :Dy, in an aqueous dispersion of a suitable binder such as Teflon. Following the spreading of the emulsion over a predetermined portion of a surface of the support member 24, the emulsion is heated to remove the water, and the resulting film is sintered to produce a strong, continuous radiation dosimeter film which is intimately bonded to the surface of the support member 24.
It has been disclosed in detail in U.S. Pat. No. 4,053,772, which has been incorporated herein by reference, that radiation can be measured on the basis of alpha particles, providing the thickness of the radiation dosimeter is maintained within critical dimensions, i.e., less than 3 mils. This teaching, coupled with the disclosure of a technique for forming the radiation dosimeter as an emulsion film, which, when heated and sintered, can form a large area uniform film within the critical thickness requirements for alpha particle sensitivity, permits the fabrication of an improved personnel radiation monitoring dosimeter badge. While the conventional personnel radiation dosimeter badge consists of a homogeneous mixture of a thermoluminescent phosphor and a binder to form a badge having a thickness of approximately 0.4 mm, the personnel radiation dosimeter badge disclosed in FIG. 3 utilizes a thin radiation dosimeter element film 42 comparable to dosimeter 22 of FIG. 1 integrally secured to a Teflon support member 44, as contrasted with the metal support member 24 of FIGS. 1 and 2.
Thus, while the binder material, i.e., Teflon, is used both as the binder for the radiation dosimeter film 42 and the support member 44, the dosimeter portion of the combination 46 is limited to the thin radiation dosimeter film 42, as contrasted with the prior art personnel radiation badge wherein the dosimeter consists of thermoluminescent phosphor/Teflon binder corresponding to the total thickness t of the combination 46. Thus, the radiation dosimeter film 42 is of a thickness between approximately 1 and 3 mils, whereas the combination 46 of the radiation dosimeter film 42 and the Teflon support member 44 is of a thickness t equal to 0.4 mm.
Referring to FIG. 4, which is a top view of the combination 46 of FIG. 3, the length and width dimensions of the combination 46 are illustrated to be 31.75 mm and 44.75 mm, which correspond to the conventional dimensions of a personnel radiation monitoring badge, thus rendering the combination 46 totally compatible with the readout apparatus employed with the conventional radiation dosimeter badge. | A thin film radiation dosimeter is secured to a plate member exhibiting sufficient mechanical strength to function as a dosimeter support member and electrical resistance characteristics which permit the plate member to function as a heating element during the readout process of the radiation dosimeter. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to read-write apparatus and methods for reading and writing information on a recording media using a read-write head which contacts the recording media.
2. Description of the Related Art
As an example of the read-write apparatus of a prior art, a magnetic disk apparatus is explained. In the magnetic disk apparatus of the prior art, the read-write head ("head" hereafter) consisting of a head slider of magnetic head flies above the surface of the recording media ( "disk" hereafter) using pressure generated by air while the disk rotates at high speed. The information is read and written under a condition that spacing between the head and the disk is almost fixed. In short, the head does not contact the disk while the diak is rotating. The head does not slide on the disk.
However, when recording wave length becomes short to improve recording-density, if the spacing between the head and the disk is kept constant, output from the magnetic head decreases. Therefore, it is necessary that flying height of the head become smaller. However, there are limits on how small the flying height can be. Recently, a magnetic disk apparatus which contacts the recording surface has been developed.
In the magnetic disk apparatus with contact recording heads, the head always contacts the disk and slides on the disk. Therefore, it often happens that both surfaces of the head and the disk are worn. In order to decrease wear of the head and the disk, the load force of the head to the disk should be decreased as much as possible (as disclosed in Japanese Patent Disclosure (Kokai) No.7-307069). However, the wear of the head and the disk is not entirely avoided. As for the wear of the head, structure not have influencing magnetic function is prepared in the magnetic disk even if the head is worn to some extent. Under this structure, some wear is permissible (as disclosed in "H. Hamilton, IEEE Trans. on Magn., Vol.27, No.6-pp 4921-4926 (1991)).
On the other hand, as for the wear of the disk, the disk is fatally wounded if the magnetic layer of the disk is greatly worn. Therefore, the wear of the disk should be avoided to the utmost. However, if the head is frequently located on a specific area (e.g. the area to store information to control file) wear progresses move quickly on the specified area.
As mentioned above, in a read-write apparatus which contacts the recording, if the head slides on the specified area of the disk at excessive times, the wear progresses on that specific area.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide read-write apparatus and methods which avoid the head slide on a specific area of the disk concentratedly to prevent the progress of the wear on the specified area.
According to the present invention, there is provided a read-write apparatus including a disk and a read-write head for reading and writing information on the disk by contacting the recording media, comprising; calculation means for calculating a slide count of the read-write head while reading and writing on the recording media.
Further in accordance with the present invention, there is provided an information processing apparatus to which a read-write apparatus is conectable, wherein the read-write apparatus includes a disk and a read-write head for reading and writing information on the recording media by contacting the disk, comprising; calculation means for calculating a slide count of the read-write head while reading and writing on the recording media, and memory means for storing the slide count calculated by said calculation means.
Further in accordance with the present invention, there is provided a method for calculating a slide count of a read-write head on a disk, comprising the steps of: accessing information on the recording media by the read-write head contacting the recording media, and calculating the slide count of the read-write head at the accessing step.
Further in accordance with the present invention, there is provided a computer readable memory containing computer-readable instructions to calculate a slide count of a read-write head on a recording media, the recording media being rotationally set, comprising: instruction means for causing a computer to access information on the recording media by the read-write head's contacting to the recording media, and instruction means for causing a computer to calculate the slide count of the read-write head while accessing the recording media.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a magnetic disk apparatus as an example of the read-write apparatus in accordance with a preferred embodiment.
FIG. 2 is a block diagram of the read-write apparatus according to the present invention.
FIG. 3 is a schematic diagram of data structure on the disk.
FIG. 4 is a schematic diagram of relation among servo sector, data sector and slide area on the disk.
FIG. 5 is a schematic diagram of one example of the data sectors corresponding to a plurality of data tracks.
FIG. 6 is a schematic diagram of relation between track pitch and slide width of the head used for the read-write apparatus of the contact recording.
FIG. 7 is a flow chart of processing of the read-write method according to the present inrention.
FIG. 8 is a block diagram of the read-write apparatus connected to an information prcessing apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention are described below with reference to the drawings.
A structure of a magnetic disk drive in which the apparatus and methods of the present invention are used will be described with reference to FIG. 1. A disk 201 is set on a spindle 202, and rotated at a constant rotational speed by the spindle 202. A slider 203 carrying a magnetic pole is mounted on a tip end of a suspension 204, and accesses the disk 201 in order to read and write information. The suspension 204 is connected to an end of an arm 205 which has a bobbin portion holding a driving coil (not shown). The other end of the arm 205 consists a voice coil motor 206, which is a type of linear motor. The arm 205 is held by ball bearings (not shown) provided in two locations, i.e. above and below a fixing axis 207, and the arm 205 can be freely rotated and/or oscillated by the voice coil motor 206. The voice coil motor 206 has a driving coil wound around the bobbin portion of the arm 205, and a magnetic circuit including of a permanent magnet (not shown) arranged to sandwich the coil and to oppose each other, and an opposing yoke (not shown).
The present invention is not limited to being applied to a magnetic disk drive in which a rotary actuator is used. It is possible to apply it to other types of magnetic disk drives, for example, a magnetic disk drive in which a linear actuator is used.
FIG. 2 is a block diagram of the read-write apparatus according to a first embodiment of the present invention. In the read-write apparatus of FIG. 2, information is read and written on disk 1 by contacting the head 5 to the disk 1. In this case, one area of disk 1 stores a control information file and the head 5 slides more frequently on this area in comparison with other areas. Therefore, the wear progresses faster on this area. In order to assist in preventing this wear, a slide count of the head 5 on each area on the disk 1 is accumulated. In accordance with the slide count, a warning is output to a user or repeat slide of the head on the specified area is avoided.
However, in the prior art, it is usual that information is read and written on the disk by a flying head 5 without contacting the disk 1. Therefore, a slide count of the head 5 on the disk 2 is not accumulated.
In the present invention, a slide count for each area of the disk 1 is accumulated by monitoring servo information recorded on the disk 1. The slide count is memorized for specified units of area of disk 1.
FIG. 3 is a diagram of a preferred embodiment for disk 1. As shown in FIG. 3, the structure comprises a plurality of concentric data tracks 4 and spoke-like servo sectors 3 located at intervals of predetermined angles on the disk 1. Servo sector 3 stores servo information for each data track. The data track 4 is divided into a plurality of data sectors 2 by the servo sector 3. Servo information of the servo sector 3 is comprised of a servo pattern, position information, synchronization signal and erased portion. The position information represents addresses of corresponding data tracks. Accordingly, the address of the data track corresponding to head position is recognized by the position information of the data track in the servo pattern.
As shown in FIG. 2, head 5 reads servo information 6 from servo sector 3 at predetermined intervals while disk 1 is rotating. The servo information 6 is sent to a head position detection section 7. The head position detection section 7 detects the track position (address) of the head on the disk 1 according to the servo information 6. A head position control section 8 executes seek control and track following control. Seek control moves head 5 to specific areas of the data track 4 to access information on the disk 1. Track following control accuates the location of the head 5 on the data track 4. An actuator 10 is activated through a driving section 9 according to output signal from the head position control section 8 and the head is accurately located on the data track 4. Such detection of track position of the head 5 from the servo sector 3 is executed while rotating the disk 1. Therefore, a slide count calculation section 11 accumulates the slide count representing the number of slides that head 5 slides on one data track 4. The count is based on the track position information from the servo sector 3. The slide count is accumulated according to units of the data sector 2. The detailed method of count accumulation is explained with reference to FIG. 4.
FIG. 4 is a schematic diagram showing the relation among the servo sector, the data sector and the slide area on the disk 1. Assume that n pieces of the servo sectors 3 are located from position 1 to n along the rotation direction, and m pieces of data track 4 are located from positions 1 to m toward concentric circles (from inner circle to outher circle) on the disk 1. The number of data sectors 2 between servo sector i and servo sector i+1 along data track j is (j-1)×n+i. Track position X of the head 5 is j+0.0 if head 5 is located on the center of data track J. Then track position X of the head 5 is j+0.5 if head 5 is located between data track j and data track J+1.
As shown in FIG. 4, assume that a track position X 1 of the head 5 is detected by servo sector i as "j 1 -0.5≦X 1 <j 1 +0.5" on data track j 1 and the next track position X 2 of the head 5 is detected by servo sector i+1 as "j 2 -0.5≦X 2 <j 2 +0.5" on data track j 2 . In this case, the slide count calculation section 11 determines that head 5 on servo sector i is located on data track j 1 and the head 5 on servo sector i+1 is located on data track j 2 . In addition, the slide count calculation section 11 determines that the head 5 slides data sector (j 1 -1)n+i, . . . , data sector (j 2 -1)n+i from data track j 1 to data track j 2 while the head position moves from the track position X 1 to the next track position X 2 . A memory 12 includes a plurality of areas which store the slide count by data sector units. As mentioned above, (m×n) pieces data sectors 2 are included in disk 1. Therefore, for the area corresponding to data sector 2 to be slided by the head 5, the slide count is accumulated.
Next, an example of the slide count calculation section 11 is explained. Assume that the number "n" of the servo sectors is "60", number "m" of the data track is "1000", the track position "X 1 " of the head 5 on 3rd servo sector is "3.2", the track position "X 2 " of the head 5 on 4th servo sector is "6.8". In this case, the slide count calculation section 11 decides that the head 5 on 3rd servo sector is located on 3rd data track and the head 5 on 4th servo sector is located on 7th data track. In addition to this, the slide count calculation section 11 decides that data sector #123 on the 3rd data track, data sector #183 on the 4th data track, data sector #243 on the 5th data track, data sector #303 on the 6th data track, data sector #363 on the 7th data track are slided over while the head slides from the track position X 1 (=3.2) to the track position X 2 (=6.8). In memory 12, the slide count is increased for the five areas coresponding to five data sectors (123, 183, 243, 303, and 363) by "1".
FIG. 5 is a diagram of one example of the data sectors corresponding to a plurality of the data tracks. In case that K(≧2) pieces of the data sectors are slid over between servo sector i and servo sector i+1, all areas of each data sector are not slided. In the above example, five data sectors are respectively divided by five areas from 3rd servo sector to 4th servo sector as shown in FIG. 5. In data sector #123, first oblique line area near servo sector #3 is slid over. In data sector #183, second oblique line area is slid over. In data sector #243, third oblique line area is slid over. In data sector #303, fourth oblique line area is slid over. In data sector #363, fifth oblique line area near servo sector #4 is slid over. Therefore, each data sector is respectively divided as fine units and the slide count is accumulated by unit of the fine unit of the data sector. The number of the fine units of each data sector is set as the maximum of number of data tracks 4 which the head 1 slides over at a time.
Next, a second embodiment of the slide count calculation section 11 is explained. In this embodiment, a weight is multiplied by the slide count according to the slide situation of the head. In short, a condition of the slide count for each area on the disk is correctly evaluated. As a method of weight-multiplication, it is considered that a large weight is set in the case of a fast slide speed, a small weight is set in case of the head passing a particular part of the data sector, and a large weight is set in case of the data sector whose signal quality is poor.
Next, the slide count calculation section 11 according to another modification of the first embodiment is explained. FIG. 6 is a schematic diagram of the relation between track pitch and slide width of the head used for the read-write apparatus of the contact recording. As shown in FIG. 6, in the head of the contact recording, a slide width w for a head section to contact the data tracks is larger than a track pitch p of one data track-width (a magnetic head-width). In short, in addition to one data track to be accessed, the head slides over other data tracks. Therefore, as for the other data tracks, a number of slides is counted to detect areas of the disk to be actually slided by the head section. In this case, in case data track n is detected to be located by the magnetic head according to the servo information, all data tracks from data track n-m to data track n+m are decided to be actually slid. ##EQU1##
If the head section slides over a part of an inner side data track or an outer side data track, all parts of the inner side data track or the outer side data track is determined to be slid over and the number of slide is counted for the inner side data track or the outer side data track. ##EQU2##
If the head section slides over half of the inner side data track or the outer side data track, the number of slide is counted for the inner side data track or the outer side data track. If the head section slides over less than half part of the inner side data track or the outer side data track, the number of slide is not counted for the inner side data track or the outer side data track. ##EQU3##
Even if the head section slides over a part of the inner side data track or the outer side data track, the number of slide is not counted for the inner side data track or the outer side data track.
In case (iii), when the number of slide is counted for the inner side data track or the outer side data track, 1/(2P) of surplus of (W-P)/(2P) may be used as weight for multiplication.
Next, the read-write apparatus according to a second embodiment of the present invention is explained. The architecture of FIG. 2 may also be used as the read-write apparatus according to the second embodiment. FIG. 7 is a flow chart of processing of the read-write apparatus according to the second embodiment. In the second embodiment, a relocation section 13 in FIG. 2 is added to the first embodiment described above. Relocation section 13 relocates the information by units of area on the disk 1 according to the slide count stored in the memory 12. Determination of relocation is made after a predetermined period of time has elapsed. For example, recorded information in one area whose slide count is the largest is transferred to an area whose slide count is the smallest in the disk 1. In this case, if no information is recorded in the other area, the recorded information in the one area whose slide count is the largest is simply transferred. In case information is already recorded in the other area, the information recorded in the one area and the other area are exchanged. Of course, index data (not shown in the Figs.) representing an area address to record the information is updated according to the transfer. In this way, the slide count of each area on the disk is normalized. FIG. 8 is a block diagram of the magnetic disk apparatus of the second embodiment connected to an information processing apparatus. As shown in FIG. 8, in the information processing apparatus, the slide counts in memory 12 is output to the relocation section 13. The relocation section 13 in the information processing apparatus executes relocation of the information of each area on the disk 1 according to the slide count.
In another embodiment, one data file on the disk consists of plural data blocks each of which includes an identifier. The data file is relocated so that the slide count is not above predetermined value per unit of the data block. For example, one data block may correspond to one data sector. In this case, the data block is relocated according to the slide count of each data sector. However, in recent data formats, one data block corresponds to plural data sectors by using ZBR (Zone Bit Recording). In this case, the one data block is relocated according to one data sector whose slide count is the largest among the plural data sectors.
Furthermore, the information may be relocated in order to collect in one area plural data tracks whose slide count is respectively large. In this case, a number of data tracks to which the head crosses decreases. In this way, a number of data tracks to be slid decreases. Otherwise, a plurality of empty areas to which the head does not access are created on the disk. In this way, concentrated slide on a specified data track on the disk is reduced.
In relocation processing of the second embodiment, as shown in FIG. 2, the relocation section 13 outputs a relocation signal (transfer source area address and transfer destination area address) to the head position control section 8 according to the slide count in the memory 12. The head position control section 8 drives the actuator 10 through the driving section 9. Therefore, the head is moved to the area corresponding to the transfer source address and the transfer destination address by driving of the actuator 10.
As shown in FIG. 8, the functions of the slide count calculation section 11, the memory 12, the relocation section 13 are included in the information processing apparatus, the information processing apparatus outputs the relocation signal to the head position control section 8 in the magnetic disk apparatus.
Next, the read-write apparatus according to modification of the second embodiment is explained. In the modification, in addition to the slide count, the quality of the read-out signal (resolution, signal-amplitude), error-rate of the read-out signal and servo signal, and the condition of spindle motor (rise time) are monitored by the information processing apparatus to which the magnetic disk apparatus is connected in FIG. 8. Inside the information processing apparatus, reliability of the disk is decided. For example, in case the maximum of the slide count for each area on the disk is above a predetermined value and close to the span of life, a warning signal is output through the information processing apparatus. In short, backup of information on the disk and update of the magnetic disk apparatus is requested for the user. The warning signal may be a buzzer or display on the monitor. Furthermore, at same time of the warning signal, a number of rotation of the disk is decreased to, for instance, 1/2 and recording frequency is changed to half of original frequency by a rotation control section 14 in FIG. 8. In the magnetic disk apparatus of contact recording, if the number of rotation of the disk decreases, slide speed of the head and the disk also decreases. In short, progress of wear for the head and the disk is decreased and the span of life of the disk is prolonged. Therefore, even if the warning signal is outputted, the backup processing is executed with enough time because the span of life is extended. In this case, if relative speed between the head and the disk decreases, amplitude of the read-out signal of the head also decreases. In order to avoid this problem, a special MR head in which the amplitude of read-out signal does not depend on the relative speed can be used.
Next, the read-write apparatus according to another modification of the second embodiment is explained. In general, if dust or other defect exists on an area of the disk, the read-out signal from the area by the head includes an error. Therefore, in another modification of the second embodiment, the dust or defect on the disk is detected using the error of the read-out signal and recovery processing is executed. In the magnetic disk apparatus of contact recording, it is desired that surface of the disk is flat to the utmost to prevent a headcrash. However, a production condition or use situation may create a defect on the surface of the disk, or the dust may be attached to the surface of the disk. In such instances, it is impossible to read and write information by normally contacting the head to the disk. Therefore, in addition to accumulating the slide count on the disk, the read signal of each area on the disk is monitored. In case the read signal of one area includes error several times, the one area of the disk is decided to include the defect and recovery processing is executed. Because the wear progresses on the head and the disk if the head repeatedlly slides over one area including the defect (e.g., physical projection or hole) on the disk. Therefore, in another modification of the second embodiment, in case the read signal of one area includes error several times, recorded information on the data track including the defect by unit of one data sector is saved to another data track. In addition to this processing, the head is prohibited from being located on the data track which includes the error in order to prevent damage of the head and the disk. As shown in FIG. 6, in case the slide width W of the head section is larger than the track pitch P and data track n includes the defect, recorded information from data track n-m to data track n+m by unit of one data sector is saved to other data track (m=(W-P)/(2P): raised to the next integral number). In addition to this processing, the head is prohibited from being located on the data track from data track n-m to data track n+m.
A memory can be used to store instructions for performing the process described above. Such a memory can be, for example, a CD-ROM, floppy disk, hard disk, magnetic tape, semiconductor memory.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. | In the read-write apparatus of the present invention, concentrated sliding of the read-write head in a specific area on the recording media is reduced. The recording media is rotationally set and the read-write head contacts the recording media to read and write information on the recording media. While the read-write head is accessing (read/write) the information on the recording media, a slide count calculation section calculates a slide count of the read-write head by monitoring the servo information of the recording media. The memory section stores the slide count calculated by the slide count calculation section by unit of access area. The relocation section suitably relocates the information recorded on the recording media in accordance with the slide count by unit of the access area. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an assembly to be worn about the head of a person and structured to include a darkened, transparent material lens structure functional as sunglasses but also positionable into an outwardly extending overhanging relation to the eyes of the wearer and out of the viewing path relative thereto so as to effectively function as a visor.
2. Description of the Prior Art
The prior art is of course replete with various types of sunglasses and/or shading devices structured to accomplish viewing by the wearer directly through darkened lens portions which effectively serve as sunglasses. Alternately the structure of the prior art device extends in an overhanging, outwardly extending relation to the eyes of the wearer and thereby serves as a shading or visor structure. Typically, prior art devices include attachment to the wearer through some type of support frame including an elongated temple portion set on the sides of the head and somehow connected in supported relation on or about the ears of the wearer. Also, it is typical for such structures to be depending from or supported on the bridge of the nose. While apparently operable or functional for their intended function, prior art devices of the type set forth in the following U.S. Patents are frequently not efficiently usable as both eyeglasses and visor structures.
For example, U.S. Pat. No. 2,616,082 to Creighton discloses a combination eye shade and sunglasses wherein temple-type structures 88 extend back along the temples of the head of the wearer similar to typical eyeglasses and wherein the lens portions thereof are supported on the bridge of the nose or substantially adjacent thereto in a generally conventional fashion. Mendelsohn, U.S. Pat. No. 2,582,554, and Hanford, U.S. Pat. No. 2,632,164, disclose generally similar structures. One problem associated with the structures disclosed in the aforementioned patents also relates to the method of properly positioning the shading or lens portion of the assembly in a preselected position. Typically, such devices used to position the assembly as intended are either over complicated, or inefficient and difficult to manipulate and/or attend to such positioning. The patents to Vivolo, U.S. Pat. No. 2,968,812; Muller, U.S. Pat. No. 3,212,102; and Hoffman, U.S. Pat. No. 3,295,143, all disclose a shading structure or glare shield utilizing some type of glare or sun shield or shading structure positionable at a preselected location relative to the eyes of the wearer of the assembly.
Prior art devices generally relating to the same subject matter but differing therefrom at least to some extent include the patent to Jean Jr., U.S. Pat. No. 4,616,367, disclosing a soft material headband with separate lens structures positionable into and out of overlying, viewing relation to the eyes of the wearer. Similarly, Daigle, U.S. Pat. No. 4,712,254, is directed towards the headband and eye piece combination also wherein the lens portions are completely hidden when not in use as sunglasses. Finally, Schmidthaler, U.S. Pat. No. 4,578,822, discloses a visor type article including a relatively rigid arcuate shaped band member and an adjustable elastic strap cooperative with the band member to encircle the wearer's head. The device incorporates the concept of a replaceable visor structure having marginal end portions adapted to be releaseably inserted into a slot in a proper and preferred location. This structure does not incorporate the visor being also used as sunglasses, however.
While the structures set forth in the above-noted patents are considered to be operable for their intended function, there is still a recognized need and room for improvement in a combined visor structure and sunglasses wherein the wearer thereof can selectively position proper darkened viewing lenses between two operable positions to accomplish both functions.
SUMMARY OF THE INVENTION
The present invention relates to an assembly which can be selectively worn either as sunglasses or as a visor structure. A mounting means used to secure the entire assembly in proper positioning about the head of the wearer comprises a headband type structure formed of a relatively flexible material preferably such as plastic so as to readily adapt itself to the configuration of the wearer's head. Further, some type of adjustment feature may be incorporated therein such that the length or more specifically the circumference size is adjustable to adapt to the size of any wearer's head.
A sweatband and/or combined moisture absorber and cushioning member may be removably mounted along a portion of the interior surface of the headband so as to add not only comfort but serve as a "sweatband" in order to remove excess moisture from the contacted surfaces on the wearer's head.
A bracket extends outwardly from a frontal portion of the headband in substantially overhanging relation to the face and/or eyes of the wearer. The bracket has a transverse dimension to extend substantially across the face and extends outwardly from the headband a sufficient distance to allow a depending support of a lens structure thereon. The lens structure thereby depends in a downwardly hanging and specifically overlying relation to the eyes of the wearer such that the path of viewing of the wearer passes directly through the lens structure. In order to accomplish proper protection of glare from reaching the eyes, the lens structure may be formed, at least in part, from a darkened and/or polarized, transparent material through which the wearer may readily view.
The lens structure is movably mounted and connected to the bracket structure by positioning means secured at opposite, correspondingly positioned ends of both the lens structure and the bracket structure such that the lens structure may be selectively positioned and removably maintained in either one of a viewing position or shading position. The shading position of the lens structure is defined by a substantially outwardly extending relation of the lens structure to the face of the wearer as well as the bracket and in overhanging but not overlying relation to the eyes of the wearer. When in the aforementioned shading position, the lens structure provides a shading of the eyes and face of the wearer similar to that accomplished by an outwardly extending rim of a hat or cap. Due to the specific structure, placement and relative dimensions of the various components comprising the positioning means, the lens structure may be easily positioned into either of the viewing or shading position and maintained in such position without a significant tendency of the lens structure to be inadvertently displaced therefrom.
In addition, the lens structure is specifically dimensioned and configured to be removed from any supported contact on the bridge of the nose or other portions of the face. To the contrary, the lens structure is supported entirely by the bracket structure whether the lens structure is disposed in either of the viewing or shading positions.
Other features of the lens structure include side visors which are disposed in somewhat transverse relation to the remaining viewing portion of the lens structure and extend substantially sideways in overlying relation to the corner or outer ends of the eyes in order to prevent glare or unwanted light from passing into contact with the eyes from this outside position.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a top sectional view showing the relative cooperative positioning and interconnection of the components of the subject assembly.
FIG. 2 is a front plan view of the assembly wherein a lens structure thereof is shown in a viewing position.
FIG. 3 is a side view of the embodiment of FIG. 2.
FIG. 4 is a side view in partial cut-away wherein the lens structure is shown in a shading position.
FIG. 5 is a detailed view in partial cut-away in section along line 5--5 of FIG. 2.
FIG. 6 is a detailed view in section and cut-away along line 6--6 of FIG. 1.
FIG. 7 is a sectional view in partial cut-away along line 7--7 of FIG. 1.
FIG. 8 is a detail view in partial cut-away showing a configuration of the embodiment of FIG. 6 and taken along line 8--8 thereof.
FIG. 9 is a detail view in partial section of yet another embodiment of the positioning means of the present invention.
FIG. 10 is a detail view in partial cut-away of cooperative components of the embodiment of FIG. 9.
FIG. 11 is an end view taken along line 11--11 of FIG. 9.
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 through 7, the present invention is directed towards a combined sun visor and sunglasses assembly generally indicated as 10. The assembly includes a mounting means in the form of a headband 12 for securing the assembly about the head of the wearer. The headband 12 is formed from a somewhat flexible and adaptable material, such as plastic, and is of sufficient length to extend in completely surrounding relation about the head of the wearer. In the embodiment shown in FIG. 1, the headband 12 includes two opposite ends 14 and 16 which are separable but adjustably interconnected to one another by a plurality of cooperative apertures and outwardly extending teeth 18 and 20 respectively. Therefore, while the adjustable feature associated with the head band 12 is defined by the preferred and selected interconnection of the opposite ends 14 and 16. Any other adjustment means may be utilized and still be within the intended scope of the present invention.
Also in the embodiment of FIGS. 1 and 7, the headband 12 includes an elongated removably attached strip 24 formed of a soft, flexible and possibly resilient material which is also moisture absorbent. Accordingly, the elongated strip may define a "sweatband" extending along at least the frontal portion of the headband 12 as best shown in FIG. 1. The headband 12 may include any type of removable connection such as a hook and loop type fastener 26 commonly known and commercially available under the trademark "VELCRO." By virtue of the removable attachment of the strip 24, it may be easily removed and reattached in the preferred position shown in FIGS. 1 and 7 for purposes of replacement and/or washing. Therefore, a plurality of replacement bands 24 could be supplied with the assembly at the time of purchase or obtained independents thereof.
The assembly 10 of the present invention further comprises a bracket structure 30 including a substantially concave mounting strip 32 adapted to the configuration of the frontal portion of the headband 12 as at 12═ (see FIGS. 1 and 7) and secured thereto such as by connectors such as staples or like connectors 34. In order to ensure that the wearer will not be subjected to any unnecessary discomfort, the elongated strip 24 or sweatband effectively covers the correspondingly positioned end of each of the connectors 34 so that such ends will not come into contact with the skin of the wearer. The bracket structure 30 includes two outwardly extending arms or support portions 36 having one end integrally or otherwise attached to the mounting strip 32 and the opposite end disposed and structured to removably support a lens structure generally indicated as 40 thereon. As best pictured in FIGS. 2 and 4, the bracket structure 30 also includes a top or cover member 38 extending along the length of the bracket structure and integrally secured or interconnected to the outwardly extending arms 36. As also shown in FIG. 2, the top or cover portion 38 of the bracket structure 30 is spaced from an upper peripheral edge 42 of the lens structure 40 in order to facilitate selective rotational movement of the lens structure relative to the bracket.
The lens structure 40 includes two lens portions or viewing portions 44 which, when positioned in the "viewing position," disclosed in FIGS. 2 and 3, are disposed in directly overlying relation to the eyes of the wearer such that the viewing path of the wearer is directly through the lenses or viewing portions 44 of the lens structure 40. Proper shading is provided by virtue of the formation of the lens structure 40 and particularly the lens portions 44 thereof from a darkened and/or polarized transparent material.
Further structural features associated with the lens structure 40 is its connection to a leading portion of the bracket 30. More specifically two oppositely disposed ends 48 of lens structure 40 are disposed in overlapping and/or confronting engagement with the exterior surfaces of the outwardly extending arms 36 of the bracket structure 30 as clearly shown in FIGS. 1, 2 and 5. These opposite ends 48 have a positioning means at least partially mounted thereon in the form of a first member projecting outwardly as at 49. This first member or portion of the positioning means is defined by two intersecting outwardly projecting arms 50 and 52 having a common substantially centrally located junction from which an outwardly extending finger projects as at 54 (see FIGS. 4 and 6). Similarly, the positioning means includes a receiving socket in the form of two transversely intersecting channels 56 wherein a centrally disposed aperture is formed at the junction of such channels 56 and is indicated as at 58 (see FIGS. 6 and 8). The transverse channels 56 are disposed, configured and dimensioned to removably receive the outwardly extending arms 50 and 52 therein but allow pivotal movement of the lens structure 40 through an arc of substantially 90 degrees or until the transverse arms 50 and 52 are rotated to be received in the next adjacent sockets 56.
Another embodiment of the positioning means is shown in FIGS. 9, 10 and 11 wherein an outwardly extending finger 54 similar to the finger 54 in the embodiment of FIGS. 5, 6 and 8 extends outwardly from the exposed surface of the end 48. However, in this embodiment the transverse outwardly projecting members 52 and 54 are deleted and instead a single outwardly projecting nipple as at 75 is integrally formed. The nipple 75 extends in spaced relation to the finger 54 and is dimensioned to be received within one of two spaced apart apertures and/or sockets 78 and 80 integrally formed in the end portion 36 as clearly shown in FIG. 10. FIG. 11 shows that both the finger 54 and the nipple 75 project outwardly a sufficient degree to extend into the respective receiving aperture 58 explained with regard to the structure of FIG. 6 and also the two apertures 78 and 80 respectively. More specifically, rotation of the lens structure 40 from a covering relation as shown in FIG. 3 and an outwardly extending or shading position as shown in FIG. 4 is accomplished and maintained by changing the positioning of the nipples 75 from the aperture 78 and to the aperture 80.
At all times during positioning and rotational movement of the first member 49 relative to the transverse sockets 56, the outwardly extending finger is maintained substantially and at least in part within the receiving central aperture 58.
Therefore, the positioning means generally indicated in FIG. 1 as 58 allows for the selective positioning and removable maintenance of the lens structure 40 in either the viewing position as pictured in FIGS. 2, 3 and 7 or the shading position as pictured in FIG. 4. Other structural features particularly of the lens structure include side visors 60 which may be formed of a similar transparent, darkened or polarized material from which the lens portions 44 are formed, but which are arranged in substantially transverse relation thereto so as to cover the outer ends or corners of the eyes of the wearer thereby preventing any inadvertent light or glare from passing into the eyes from this outer position. The side visor 60 may be formed integral with the opposite ends 48 on the lens structure as clearly shown in FIGS. 3, 4, 5 and 7.
Now that the invention has been described, | A combination sun visor and sunglasses assembly including a mounting structure designed to surround the head of the wearer similar to a headband wherein the lens structure or viewing portion of the sunglasses are positionable between an overlying, normally viewing position relative to the eyes of the wearer or an outwardly extending, shading position similar to an orientation of a visor structure in overhanging, shading position. | 8 |
BACKGROUND OF THE INVENTION
Present curtain rod mounting brackets generally allow the mounting of one or two curtain rods at the same height. Most present curtain rod mounting brackets do not, however, allow for the simultaneous mounting of curtain rods at different heights. This drawback limits the variety of window treatments available with such curtain rod mounting brackets.
With present curtain rod mounting brackets, the mounting of more than two curtain rods at different heights generally requires the installation of additional brackets. The use of additional brackets increases the complexity of installation and the cost of mounting the curtain rods; the consumer must purchase and install additional brackets and the manufacturer and seller must maintain an inventory of the additional brackets.
Some curtain rod mounting devices require different left and right brackets. In this case, costs and complexity are again increased, as the consumer must buy both types of brackets, the manufacturer must produce an additional type of bracket, and the manufacturer and seller must maintain an inventory of the additional brackets.
Further, some brackets are quite complicated, increasing manufacturing costs and difficulties in installation.
Other brackets require specific types of window frames and thus lack the versatility necessary for use with a wide variety of window frame and wall types.
Many brackets only accommodate a single size of curtain rod.
U.S. Pat. Nos. 2,099,770 and 4,399,917 overcome some of the drawbacks associated with standard curtain rod mounting brackets by allowing the mounting of multiple curtain rods at different heights.
U.S. Pat. No. 2,099,770 is a curtain fixture that can be attached to a window frame without the use of screws or nails. The fixture is held in place by the force of springs that urge hinged arms together, clamping the window frame between the arms. Brackets for holding curtain rods can be positioned at various heights by engaging two of a number of vertically aligned hooks positioned at various heights on one of the bracket's arms. This curtain fixture requires different left and right brackets.
U.S. Pat. No. 4,399,917 is a dual curtain rod assembly and includes two curtain rods as well as mounting brackets and spacer bars that hold the two rods a fixed distance apart, one directly above the other, forming a rigid structure for mounting on a wall.
Though U.S. Pat. No. 2,099,770 offers the advantage of mounting multiple curtain rods at a variety of heights, its springs and hinged arms increase manufacturing costs and the difficulty of installation. Further, as this device uses spring tension for attachment onto window frames, it may not be able to support heavy curtains and curtain rods. Also, this device can only be mounted on certain types and sizes of window frames. In this fixture, the left and right brackets are different, increasing manufacturing and inventory costs and increasing installation complexity.
U.S. Pat. No. 4,399,917 allows the mounting of only two rods, limiting the range of window treatments the device can provide. This device requires the user to assemble the structure, as well as position it on a wall or window frame. As the dual curtain rod assembly can be quite large and cumbersome, installing the assembled structure may be difficult.
Moreover, in the devices described in either patent, variation in vertical positions of the curtain rods is limited. In U.S. Pat. No. 2,099,770, the maximum separation between curtain rods is the width of a window frame member. In U.S. Pat. No. 4,399,917, the distance between the curtain rods is fixed by the length of the brackets and spacer bars. Neither device allows the user to stagger the curtain rods, mounting the rods alternately closer to or further from the window frame, depending on the height at which the rod is mounted. Such a feature would greatly increase the variety of available window treatments.
It would therefore be desireable to provide a mounting bracket that will allow the mounting of a plurality of curtain rods at various heights and alternately closer to and further from the window frame.
It would also be desireable to provide a mounting bracket that can accommodate more than one size of curtain rod.
It would be still further desireable to provide a mounting bracket that is inexpensive to manufacture, simple to install and is easily customizable.
It would be still further desireable to provide a mounting bracket that can be used on a large variety of wall and window frame types.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a mounting bracket that will allow the mounting of a plurality of curtain rods at various heights and alternately closer to and further from the window frame.
It is another object of this invention to provide a mounting bracket that can accommodate more than one size of curtain rod.
It is still another object of this invention to provide a mounting bracket that is inexpensive to manufacture, simple to install and is easily customizable.
It is still another object of the invention to provide a mounting bracket that can be used on a large variety of wall and window frame types.
These and other objects of the invention are accomplished in accordance with the principles of the invention by providing a mounting bracket for use in mounting multiple curtain rods of varying sizes at various heights. The mounting bracket is composed of a plurality of bracket segments with each bracket segment including a number of rod support flanges. Each of the rod support flanges has hook means for engaging slots in curtain rods. The bracket segments are removably attached to one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of this invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference numbers refer to like parts throughout and in which:
FIG. 1 is a front elevation view of the mounting bracket fixed to a window frame and supporting curtain rods at various heights;
FIG. 2 is a perspective view of the mounting bracket;
FIG. 3 is a side elevation and section of a portion of the mounting bracket shown in FIG. 2 with a curtain rod mounted on one rod support flange;
FIG. 4 is a side elevation and section of a portion of the mounting bracket shown in FIG. 2 with a curtain rod mounted on two rod support flanges;
FIG. 5 is a perspective view of an alternative embodiment of the mounting bracket;
FIG. 6 is a side elevation and section of a portion of the mounting bracket shown in FIG. 5 with a curtain rod mounted on one rod support flange; and
FIG. 7 is a side elevation and section of a portion of the mounting bracket shown in FIG. 5 with a curtain rod mounted on one rod support flange.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Mounting bracket 10 is composed of a number of bracket segments 15 joined together at joints 50 that are scored or otherwise weakened to allow for easy removal of individual bracket segments 15 (see FIG. 2). Bracket segments 15 are arranged in a staggered pattern, having longitudinal axes that are coincident with two parallel and offset axes. Mounting bracket 10 may be composed of sheet metal or another suitable material such as ABS (acrylonite butadiene styrene).
Support plate 45 has front face 55 and rear face 56, which is mounted against wall 5 (see FIG. 3). Support plate 45 has holes 40, which allow bracket segment 15 to be secured to wall 5 by means of nails, screws or like fasteners. Adhesives or tape may also serve to secure support plate 45 against wall 5.
Rod support flanges 60 and 70 extend from the front face 55 of support plate 45, generally orthogonally to front face 55. Rod support flanges 60 and 70 are adapted to support two sizes of curtain rods: a larger curtain rod 80, and a smaller curtain rod 85. Rod support flanges 60 and 70 have hook means 65 and 75 to engage slots 82 and 87 in curtain rods 80 and 85.
In the case of the larger curtain rod 80, rod support flanges 60 and 70 are situated so that their respective hook means 65 and 75 can engage slots 82 at the top and bottom of each end of the larger curtain rod 80.
In the case of the smaller curtain rod 85, rod support flange 60 is of sufficient width so that hook means 65 can engage slot 87 in smaller curtain rod 85, while lower edge 89 is in contact with smaller curtain rod 85 so that smaller curtain rod 85 is secured to rod support flange 60.
When mounting bracket 10 is composed of an odd number of bracket segments 15, the brackets are interchangeable from one side of a window to the other, with the "right" bracket being the "left" bracket inverted, and vice versa. Further, given an odd starting number of bracket segments in a particular bracket, it is always possible to construct matching pairs of brackets of fewer numbers of bracket segments by breaking off appropriate bracket segments 15. This interchangeability reduces the costs associated with producing different left and right brackets and keeping an inventory of different brackets.
The various combinations and permutations of rod support flanges enable the installer to hang a variety of different types of window treatments from the same set of mounting brackets 10, and to change the window treatment from time to time without having to remove the mounting brackets and install new brackets each time a different window treatment is desired. Balloon valences, sheer curtains and cafe curtains, among other window treatments, and various combinations of these types of window treatments, are easily installed and changed.
In an alternative embodiment of the mounting bracket, rod support flanges 60' and 70' include two hook means 65', 67' and 77', 75' respectively, with rod support flange 60' being of a width sufficient to cause hook means 67' to contact the wall 81 of curtain rod 85 when hook means 65' engages slot 87 of curtain rod 85, securing curtain rod 85 to rod support flange 60' (see FIG. 6). Likewise, when hook means 67' engages slot 87 of curtain rod 85, hook means 65' contacts wall 81 of curtain rod 85, securing curtain rod 85 to rod support flange 60' (see FIG. 7). This alternative embodiment allows the attachment of the smaller curtain rod 85 regardless of the orientation of mounting bracket 10.
Although not achieving all of the advantages of the previously described embodiments, a further embodiment that incorporates the invention has bracket segments 15 arranged in a staggered pattern having longitudinal axes that are coincident with three or more parallel and offset axes. Thus, in a mounting bracket having three or more bracket segments 15, the third bracket segment has its longitudinal axis parallel to but offset from the longitudinal axes of the first two bracket segments.
Thus it is seen that a mounting bracket for curtain rods is provided that combines all of the necessary properties of a multiplicity of mounting brackets, while being inexpensive to manufacture, simple to install and easily customizable. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow. | This invention relates to a mounting bracket for use in mounting multiple curtain rods of varying sizes at various heights. The mounting bracket is composed of a plurality of bracket segments, with each bracket segment including a number of rod support flanges. Each rod support flange has hook means for engaging slots in curtain rods. The bracket segments are removably attached to one another. | 0 |
FIELD OF THE INVENTION
The present invention relates to a fire-control system, and in particular to a fire-control system adapted for use with a weapon firing ammunition with a relatively high trajectory or firing with low-trajectory ammunition at longer distances. The invention also relates to a method of displaying a reticle and to a computer program for executing said method.
TECHNICAL BACKGROUND
When using ammunition with low exit velocity, high trajectory or firing at targets at a significant distance, where the time of flight is significant, the weapon sight has to have certain properties. In such conditions the barrel of the weapon needs to have a considerable elevation in order for the ammunition to reach the target. A normal sight will generally not suffice, since it is difficult or impossible to have a visual contact with the target via the sight and at the same time have the correct inclination of the barrel, thus aiming is impossible. Also the sight may need to cover a considerable interval of inclinations, which introduces further limitations. In this context it should be clarified that some weapons/ammunitions have an inherent high trajectory, while others only have high trajectory when applied under certain conditions, e.g. ammunition normally following a level trajectory in shorter ranges will generally fall within the definition of high trajectory if the distance they travel to the target is considerable. For the purpose of the present invention this is the relevant definition of high trajectory.
The known solution to the above problem has been to incorporate an iron sight, similar to those used for historical long guns, with a foldable primary part including distance markings, e.g. tang sight or ladder sight, such that if the distance is known, the correct distance marking can be used. This type of sight is still used, since it provides a rugged, simple solution.
More elaborate solutions include advanced optics, mechanics and computer software for calculating optimal aiming, and movement of a physical light-source inside the sight (see e.g. WO2004001324).
Though functional, more elaborate solutions generally are too complicated and thus not as rugged as one would prefer for field use or too heavy to be handheld with maintained user friendliness. The existence of moving parts inside the sight generally also increase power consumption, increase the response time, and makes the sight less versatile.
The present invention aims at providing a fire-control system relating to these and other drawbacks in prior-art.
SUMMARY OF THE INVENTION
When using high-trajectory ammunition in a field condition it is obviously important to maintain an elevated awareness regarding the events in the surroundings. Therefore it is beneficial and desired to have a fire-control system that does not include optics or electronics distorting the field of view, e.g. an optical or electronic system that creates a real or imaginary image of the target which is not in the line of sight between the aiming eye of the user and the actual target. Also, it is beneficial to be able to look at the target with the other eye while aiming.
The present invention aims at alleviating or eliminating the above and previously mentioned drawbacks and achieving the above benefits by the provision of a fire-control system in accordance with claim 1 , and a method of displaying a reticle in accordance with claim 10 and a computer program in accordance with claim 15 Further embodiments are defined in the dependant claims.
It should be noted that even though the present fire-control system is especially well adapted for the purposes mentioned in the introduction, it may be used on any weapon to increase precision and first shot accuracy. It should also be noted that though the inventive fire-control system will been described by specific embodiments, it is, unless technically unfeasible, possible to add, remove or combine individual technical features of the sight to create new embodiments, not described. This is particularly true for the features defined in the appended claims.
To this end an inventive fire-control system comprises:
a housing; partially reflective optics, through which a user may observe a target and receive visually displayed information simultaneously; a light source, for visualization of a reticle to the user via the partially reflective optics; means for receiving a measure of the distance to the target; a processor, for determining the adequate position of the reticle, based on the distance to the target, and for controlling the light source to emit light so that the reticle is visualized at the adequate position; wherein the light source is an capable of selectively emitting light in well defined locations on its surface. According to one or more embodiments the fire-control system may also comprise a battery charge controller.
The use of said array provides several advantages over prior art, and in one or more embodiments the array is a one-dimensional array. A one-dimensional light-emitting array is in this context defined by a light source capable of emitting light from well-defined points on its surface, along one specific direction. The light-emitting array is a static component in the sense that it remains immovable during the operation of the fire-control system. A static component may be made more robust, as compared to a mobile component serving the same purpose. Further, several other components may be eliminated, such as the drive, suspension, guide means, etc. which are necessary if a mobile light source is used. This elimination reduces overall weight, chock sensitivity, power consumption and, not the least, cost.
The main purpose of the sight is obviously to assist the user in striking the target, and the fire-control system will provide a reticle to be superimposed on the target. It should be noted that there are other possibilities than to superimpose a reticle. The reticle could have another form, such as a crosshair form or a circular form, and these embodiments fall within the scope of the claim. The light-emitting array enables the display of a reticle, which is movable in a vertical direction, so as to be able to mark an aiming point for various distances to a target.
According to one or more embodiments the one-dimensional array may be curved, such as to adjust for, e.g., a known drift caused by the rotation of a projectile (i.e. the gyroscopic drift) without a need to move the one-dimensional array.
The position of the reticle is calculated on basis of the measured distance to the target. Further, the one-dimensional array makes it possible to emit light from several points of the array at the same time, which increases the functionality of the fire-control system. In the case of a miss of the target, the possibility of displaying several reticles may be useful when correcting the position of the reticle, e.g. by letting the used reticle remain on the target while another reticle is electronically moved the actual point of impact. In this way the processor may correct the calculation of the reticle so that the next firing will result in a hit.
The processor may include tables and/or algorithms regarding the performance of various types of ammunition. The apparent parameter needed is related to the trajectory for various distances, since the position of the reticle relies on this type of data. However, the processor enables far more advanced maneuvers, such as correction for wind speed, inclination, air pressure, humidity, corrections etc, and makes the fire-control system very versatile. Therefore, in one or more embodiments the fire-control system may also contain data regarding various types of ammunition, and in such cases this data is included in the acquisition of the position of the reticle. This acquisition may also include data regarding air speed, air temperature, humidity, tilt of the weapon in a cross direction, and other factors affecting the trajectory of the ammunition, and the choice of reticle. One further example is that there are two elevations for which the ammunition will hit the target, a lower elevation—resulting in a lower trajectory—and a higher elevation—resulting in a higher trajectory. Depending on the type of target, the terrain in front of the target, and the ammunition either the higher or the lower trajectory may be preferred. By providing the desired scenario to the CPU it may, if geometrically possible, show either one or both of the applicable reticles.
In the above context the term “position” relates to the position in a plane orthogonal to the line of sight between the eye of the user and the target. However, in many applications it is also important at what distance from the users eye the image of the lit part, i.e. the reticle, of the light source is located.
In one or more embodiments the light-emitting array is a two-dimensional array capable of selectively emitting light in well-defined locations on its surface. The two dimensional array makes the fire-control system even more versatile, since it enables the position of the reticle to be varied in the horizontal direction as well. This makes it possible to correct the position of the reticle in relation to offsets due to wind, poor alignment etc. The use of a two-dimensional light-emitting array facilitates software tuning of the fire-control system, making the production and quality assurance faster and less costly. When zeroing the weapon it may simply be fired at a target, after which the reticle is manually (by using input means for communication with the fire-control system) translated to the actual hit, after which the weapon is tuned for that particular type of ammunition. This results in a markedly decrease in ammunition and time consumed during tuning.
In one or more embodiments the fire-control system may be combined with equipment for infrared illumination and/or night-vision systems, which may increase the usability of the fire-control system.
The fire-control system according to one or more embodiments may also comprise a range finder, active or passive, within its housing. The use of an integrated rangefinder increases the fire-control systems versatility even further. Instead of relying on external data the user may now measure the distance to the target while looking through the fire-control system. The risk of potential misunderstanding decreases and the hit rate is likely to increase. The rangefinder is generally laser based and it should obviously not be subject to any trajectory correction, whereby a reticle related to the rangefinder may be displayed at all times when the fire-control system is in use.
The optics displaying the reticle for the user may comprise optics being adapted to create an image of the reticle which is essentially parallax free relative to the target. An essentially parallax free reticle significantly simplifies the task of the user, since there is no requirement to align any other components than to simply superimpose the reticle on the target and fire. If high-trajectory ammunition is used, the sight window through which the user observes the target is generally significantly larger than what is used for a normal telescopic sight since it should allow for a significant inclination of the weapon, and thus of the fire-control system, with maintained visual contact with the target through the fire-control system. An essentially parallax free reticle is generally created by having the optics generating an image at an infinite distance from the user, or at a typical distance for use, such as 300 m. This also means that the normal human eye may be relaxed, for the benefit of the user's ability to concentrate during long time. If the reticle is located at an infinite distance from the users eye, or 300 m, and the target is located 100 m away, there will be some parallax, though it has no significant impact on the precision of the weapon, as long as the user may still superpose the reticle on the target while looking in the fire-control system. Due to the fact that targets will be located at various distances a completely parallax free reticle is very difficult to achieve, which is why the word “essentially” have to be included. For the purpose of this invention “essentially parallax free” optics having inherent very low dependency on distance to observed object with regard to showing little or no parallax effects.
To further increase the versatility of the fire-control system according to one or more embodiments it may further comprise a gyro or other inclinometer for enabling measurement of the inclination of the fire-control system. Combined with the distance being known, a measure of the inclination makes it possible to account for an altitude difference between the fire-control system and the target, and to make the necessary corrections regarding trajectories and the calculated reticle. The gyro or inclinometer may obviously be combined with the capability of measuring the direction of the fire-control system in accordance with an established positioning standard, so that the processor of the fire-control system may calculate an absolute position of a target or itself The gyro or inclinometer may also be used for determining rate of angular change and thereby the speed of the target and aim-off (lead) necessary in regard of a moving target etc. To that end the fire-control system may also comprise a positioning system, such as a Global Navigation Satellite System (GNNS), e.g. Navstar Global Positioning System (GPS) or an alternative positioning system. A compass may also be included, for measuring the direction of a target in relation to the fire-control system.
A fire-control system according to one or more embodiments may further comprise means for communication with external sources. The means for communication may be realized by regular connectors for keypads, transfer of data etc, and may also comprise means for communication with wireless means, such as a receiver/transmitter for electromagnetic radiation, radio frequency communication, etc. There are several cases when this may constitute an advantage, one example being the fire-control system receiving information regarding wind speed or other atmospheric conditions.
A method for displaying a reticle for a fire-control system according to one or more described embodiments during targeting with specific ammunition, comprises the main steps conducted during use of the fire-control system:
acquiring distance information representing a distance to a target;
determining a position for imaging the reticle based on said distance information and trajectory information for ammunition to be used; and
controlling light emission from the array to emit light from a position of the surface of the array which via the partially reflective optics images reticle at the determined position.
In the step related to acquiring distance, may also include acquiring alternative or additional inputs may be used, some examples of which is illustrated in relation to FIG. 2 . Further, the step of acquiring distance may include the substeps of:
transmitting electromagnetic radiation towards the target;
receiving a reflection of said electromagnetic radiation from the target; and
calculating the distance to the target based on the time elapsed from the transmitting to the receiving.
A computer program for performing the method may be embodied on a computer-readable medium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the fire-control system according to a first embodiment of the invention, in a side view.
FIGS. 2A and 2B illustrate various configuration of a light-emitting array.
FIG. 3 is a block diagram illustrating the operations performed by the fire-control system of FIG. 1 .
FIGS. 4 and 5 are perspective views of a fire-control system in accordance with an embodiment of the present invention.
FIG. 6 is a perspective view of a grenade weapon having a handle adapted for control of the fire control system.
FIG. 7 is a flow chart of a method for displaying a reticle in a fire-control system in accordance to the invention.
FIG. 8 illustrates a computer program for executing the method of FIG. 7
DESCRIPTION OF EMBODIMENTS
The general structure and function of the inventive fire-control system in the embodiment of a sight 1 is described referring to FIG. 1 , which is a schematic representation of the sight, as viewed from one side. In the depicted view a target would be situated to the right, and the user to the left. The user may observe the target directly through a light channel housing an entrance window 2 , an angled narrow-banded reflector 4 , a dual lens system 6 , 8 , and a protective exit window 10 having essentially the same purpose as the entrance window 2 . The entrance window 2 may also consist of a lens, which may be used to correct for possible distortions. All components will be defined in the following, and one important feature of the optical components are that they do not disturb the light path from the target to the eye of the user to any significant degree, by introducing distortion. It is also to be understood that the sight 1 as such is non-magnifying. A user may therefore observe a target in a direct fashion and with both eyes open, as oppose to a system that may use a camera and a display, or a system shifting the light-path in some way. The general purpose of the sight is to display a reticle at the correct position. Starting from the left the entrance window 2 acts as a protective window, and is arranged to enable moist sealing and dust sealing of a practical system. The next component is the inclined reflector 4 , which is more intimately related to the imaging system and thus will be described later. Two spherical lenses 6 , 8 of the dual lens system are arranged at the other end of the light channel, opposite to the protective window 2 . The two lenses 6 , 8 , which are spherical, together perform the function of a parabolic mirror in relation to a reticle, which also will be described in relation to the imaging system. The imaging system of the fire-control system comprises a two-dimensional array 12 of light emitting diodes, preferably resonant cavity light emitting diodes (RCLED), which may be arranged to be very energy efficient, which is described in a previous application by the same applicant in relation to a single RCLED. In the following the two-dimensional array of RCLED:s will only be referred to as the “array” 12 . The array 12 may be fully controlled via input from a CPU (not shown), so as to emit light from selected portions of its surface. Light from the array 12 will pass through a first and a second lens, 14 and 16 , respectively, which together with the inclined reflector 4 generates an image of the array 12 placed in the focal plane of the lens system 6 , 8 , which in turn reflect the beams and generates a parallax free image of the array 12 for a user. By activating selected areas of the array 12 the user will consequently be able to observe a reticle (or other another type of indication) overlaying the target. The array 12 has a well defined wavelength λ a and the first and second lens 14 , 16 transmits λ a . The inclined reflector 4 reflects a portion of light having a wavelength λ a , towards the lens system 6 , 8 . The lens system 6 , 8 is adapted to reflect as much light having the wavelength λ a while transmitting light of any other wavelength. In this way a user may observe the target and the reticle simultaneously.
The imaging system, including the array 12 , the lenses 14 , 16 , the inclined reflector 4 and the lens system 6 , 8 are preferable integrated into a unit, such as to enable a rigid and robust construction able to maintain adequate precision while being handled roughly.
In one or more embodiments the light-emitting array 12 comprises a two-dimensional diode array of close-packed diodes (RCLED:s) having low power consumption. Such a diode array may be custom-built by IRnova (SE) or PRP Optoelectronics (GB). The wavelength of the emitted light is approximately 650 nm, well within the visible range, yet far enough from wavelength range where the human eye is the most sensitive (around 555 nm). The array may be quadratic or rectangular or have other more complex shapes, as will be described below.
FIGS. 2A and 2B illustrate two alternative embodiments of arrays 12 , which may be used in relation to the present invention. The array disclosed in FIG. 2A is of standard design in regard of its shape, and the array of FIG. 2B has been invented for use in the present fire-control system and has a trapezoid shape. The shorter of the parallel sides of the trapezoid has a width of about 30-50 pixels, e.g. 40 pixels, and the longer of the parallel sides has a width of about 100-140 pixels, e.g. 120 pixels. The distance between the parallel sides may be about 150-200 pixels, e.g. 175 pixels.
Giving the array a trapezoid shape will result in several advantages, all relating to the fact that the function of the array will be maintained while its area will be reduced (both as compared to a conventional rectangular array). Firstly, and perhaps most importantly, the present applicant has not revealed any significant disadvantages, which makes it easier to appreciate the advantages. One advantage is that during production the array is cut from a substrate, and the inventive design enables more arrays to be produced from the same substrate. The array of FIG. 2B is arranged in the fire-control system 1 so that the narrow end may be used to image the reticle for targets being far away. The shape of the array results in a fewer number of pixels, which increases the yield during production.
The lens system 6 , 8 may be coated so as to act as a bandpass filter, transmitting all visible wavelengths between 420 and 1100 nm but for a narrow wavelength interval including the wavelength emitted by the array 12 , which itself is reflected. The longer wavelength are used for Night Vision Device (NVD).
Since the light from the array has a wavelength of e.g. 650 nm, most light will be transmitted, and in particular light in a wavelength range where the human eye is most sensitive.
The image generated is a virtual image created at an infinite distance from the user, in order to relax the eye of the user maximally. The user may observe the image through the protective window 2 , the same window through which the target is observed. A second protective window 10 may, as have been mentioned above, be arranged in front of the lens system 6 , 8 . This protective window 10 may be inclined order to avoid reflections visible from the target area. Apart from protecting the sight from physical damage, the protective window 10 may also be coated to prevent transmission of hazardous radiation, such as infrared radiation from laser rangefinders, and in the absence of a second protective window 10 such coating may be provided on another optical surface of the system. Further, all optical surfaces may be coated with an anti-reflection (AR) coating to increase transmission. If external reflections are to be avoided the sight may be provided with a “killflash filter”.
A third part of the sight may house the optional laser rangefinder 18 (see FIGS. 4 and 5 ), which may be of standard type operating at 1550 nm (not visible with standard night-vision systems) as well as the processing hardware, software and storage capabilities utilized. Other standard wavelengths used are around 900 nm, still in the infrared, and visible light. The latter having the disadvantage of exposing a visible flash of light. The laser rangefinder 18 is operated by the user, and the result of a distance measurement is used as an input to the processing section of the sight 1 . The laser beam of the rangefinder will follow a rectilinear path, and thus a reticle for the rangefinder may be displayed at the same position in disregard of the distance to the target. The use of an integrated rangefinder 18 is preferred and preferable features for the rangefinder 18 for the intended application is high reliability and accuracy, low power consumption and low weight. In one or more embodiments the rangefinder may be tailor-made by Vectronix or JENOPTIK AG (DE), to fulfill the above preferences. These features are also important for the processing hardware, software and storage capabilities utilized. Existing possible processors include a main processor in the fire-control system and a processor in the handle (to be described referring to FIG. 6 ) both having a power consumption in an idle state of 0.1 μA. For other applications the weight and power consumption may be less important, and the sight need not be optimized in regard to the above parameters. All components of the fire-control system may preferably be statically mounted, such as the array 12 , and both the lens systems 14 , 16 and 6 , 8 , as well as the inclined reflector 4 . As has been mentioned before, this will increase the ruggedness of the fire-control system as compared to a system where interior components are movable. There may be embodiments of the present invention too, however, that offer movable components, even if this is not the preferred construction.
Apart from visualizing the reticle, the array 12 may operate as an alphanumerical display, such that it can be used to display current information regarding distance, type of ammunition, etc.
FIG. 3 is a block diagram illustrating the processing section of the inventive sight. The block-diagram is a simplified diagram with the purpose of illustrating the operations of the sight 1 . In use, data relating to a distance to a target and other optional inputs are transferred to the processor, which uses them in combination with relevant data from the memory to calculate the correct reticle. A control signal for controlling the array 12 is output from the processor, and the array 12 starts emitting light from a specific location (one or several) as a result.
The list in input section of FIG. 3 is extensive, and yet non-exhaustive. There are numerous of inputs that may be used for aiding in using the sight, whereof the type of ammunition and the distance to the target are two important inputs. One advantage of the present sight is that its construction allows it to be versatile, and basically any information affecting the trajectory of the ammunition used, or other parameters relevant for the user, may be used by the processor/microcontroller or displayed to the user. This information may also be communicated from the sight to other external units.
The distance to the target is generally measured with the rangefinder, but could also be input by the user, or by the sight receiving information by other means. The same is true for the type of ammunition, which either is detected automatically or input by the user.
The memory contains all information needed to control the sight. Such as tables and algorithms related to ammunition properties. The memory may communicate with external units such as to allow for updates, etc.
Examples of input variables include, but is not limited to: Ammunition data, type of ammunition, ammunition properties (trajectories coupled to distance, wind speed etc.); Target data, distance, relative altitude, velocity, geographical coordinates; Environmental data, air speed, air temperature, geographical coordinates; Weapon data, inclination, velocity, atmospheric pressure, wind speed, geographical coordinates; User settings, manual inputs, corrections
FIGS. 4 and 5 are perspective views of the fire-control system according to one embodiment. By comparison with corresponding reference numbers in FIG. 1 the alignment of the views of FIGS. 4 and 5 , respectively, are self-explanatory.
Apart from what has already been described, FIG. 4 illustrates a housing 20 . The housing 20 seals and protects the interior from water and impacts. The housing needs to be rigid and durable. In one embodiment it is made of extruded, high strength aluminum, which is anodized, providing a strong, rigid and durable housing with a low weight. There are other alternatives for the housing too, such as reinforced plastics or composite materials. The housing 20 has contact surfaces to other components, such as protection windows 2 , 10 etc, and the choice of material is preferably such that the housing and related components have similar properties in relation to heat expansion. If not, it will be difficult to achieve a sight having adequate properties, and the choice of material may be made freely within the boundaries of that the sight preferably fulfills a harsh specification related to temperature, moisture etc. A lower portion of the housing 20 , which portion may be a separate part attached to the housing, contains a power source in the form of a battery pack. This portion may also comprise a control device 22 for regulating the intensity of the light emitted by the array 12 . The actual control of the RCLED intensity may be performed by varying pulse length to the RCLED in such a way that the human eye interprets it like a variation in intensity. This control method is thoroughly described in the application EP 1 210 561 A by the present applicant and will not be described in any further detail here, though the relevant details of said application are incorporated by reference. Also adjusting the current in the pulses can be used to increase the range in which the intensity can be set. This is specially important when using NVD.
A key pad 24 may be used as an interface between the sight and the user. The key pad 24 has a conventional functionality and is connected to control electronics of the sight in a conventional manner.
Further, mounts 30 for mounting the sight to a weapon are shown. Connections to remote control devices are preferable wireless, using e.g. suitable means for wireless communication. The use of wireless connections simplifies the task keeping the interior of the fire-control system protected from the outside environment (moist, dust, gases). If physical connectors are desired they may be arranged for at a suitable position, e.g. for a remote control and charging/communication/auxiliary devices. The remote control may be used to simplify input during shooting, such that the user can aim at a target having the correct shooting position and input data at the same time. The remote control could have a design similar to the keypad 24 , or have a simplified design, comprising e.g. buttons for using the rangefinder and correcting the reticle only. FIG. 4 also illustrates the intensity knob 22 , which is a rotary switch used in order to adjust the intensity of the reticle. Auxiliary devices include a keyboard, a GNSS receiver, a gyro device, an inclinometer, device for communication with the ammunition and/or any other element performing functions as demonstrated above with reference to FIG. 3 . The auxiliary devices, or other types of external information, may communicate with the sight via a wire or via wireless communication, as discussed above. Wireless communication can also occur between the ammunition and the sight, such as information related to timing of the ammunition. Some or all of these devices may also be incorporated into the actual fire-control device. The connections may also be used for downloading new processing software and ammunition tables/algorithms etc.
FIG. 5 shows the fire-control system in a perspective view from a direction such that the output lens 36 and the receiving lens, 38 of the rangefinder 18 are visible. Opposite to the intensity knob 22 , the battery cap 40 is shown. For ease of maintenance the sight preferably uses standard AA batteries, available all over the world, as energy source. Of course rechargeable AA batteries as well as Lithium batteries can be used.
FIG. 6 illustrates a recoilless grenade weapon provided onto which the inventive fire-control system may be mounted, on the mount 42 . The fire-control system may then be connected to a control device, arranged on front handle 44 of the weapon. Three control buttons 46 , 48 , 50 are arranged within reach of a users thumb while gripping the front handle 44 . The communication between the control device on the front handle 44 and the fire-control system is preferably wireless, e.g. via a Texas Instruments CC2500 low power transceiver.
When using the sight the user has to switch it on and, if it is used for a new purpose, initiate it by setting some user parameters, such as the type of ammunition used, various offsets etc. When looking in the sight and pushing the LRF (Laser Range Finder) knob the user will then see a static illuminated reticle, which is used to direct the rangefinder onto a target and zeroed with the rangefinder. When the static illuminated reticle is superimposed over the target the rangefinder may be activated, e.g. by releasing the knob. This action results in that the distance to the target is measured and can be displayed by the alphanumerical display. It can also result in that a second reticle, e.g. with pulsating intensity, is displayed to the user. The user may then have the opportunity to adjust the position of the second reticle in order to compensate for target movement, wind etc, before superimposing the second reticle over the target and firing the weapon, if any of these parameters is not compensated for by the fire-control system. After firing the weapon the position of the second reticle may be adjusted yet again. The second reticle may differ visually from the first, if displayed at the same time, in order to avoid confusion. The skilled person realizes that this can be achieved in several different ways.
Correction of the position of the reticle as a response to the inclination of the weapon will be described next. In order to achieve such a correction the sight, or the weapon, has to be provided with a sensor for measuring inclination, e.g. an inclinometer from Freescale Semiconductor. If the distance to the target was the only parameter to be considered the inclination in the length direction of the weapon would be accounted for in the initial target acquisition, i.e. by measuring the distance to the target. Another parameter that has to be accounted for, however, occurs when firing at a target being positioned at a lower or higher altitude than the weapon itself. Provided that the weapon receives information regarding difference in altitude this inclination too is accounted for when performing the initial acquisition of the target. This may be achieved by combining the information from the distance measurement with information from an inclinometer, detecting the inclination in the length direction of the weapon. The information may also be acquired from other sources. An inclination, or tilt, in the cross direction of the weapon may occur when the user is tilting the weapon by mistake. The tilt is less predictable than the inclination in the length direction, since it may be altered between the acquisition of the target and the actual moment of firing the weapon, and it is self explanatory how the tilt may cause a significant miss of the target. One way of eliminating the problem of tilt may be to introduce a virtual horizon, or other indication of how the weapon should be tilted in order to reach a horizontal position in the cross direction. According to another embodiment of the present invention, however, the CPU rapidly determines, by analyzing a signal from the inclination sensors, the tilt of the weapon, after which the position of the reticle is adjusted accordingly. One beneficial effect of the latter technique is that the information displayed to the user may be kept at a minimum, shortening the time between target acquisition and the first shot fired at the target. If the tilt of the weapon is too large, so that the adjusted position of the reticle is outside of the capacity of the array, the system may be adapted to provide an indication regarding how the weapon should be tilted back. One example of such an indication may be a twinkling arrow, or other shape that may not be confused with the reticle.
The method according to the present invention, as illustrated in the drawings is suitable for implementation with aid of processing means, such as computers and/or processors. Therefore, there is provided a computer program comprising instructions arranged to cause the processing means, processor, or computer to perform the steps of the method according to any of the embodiments described or the method necessary to make the fire-control system according to any embodiment described operate in the desired manner. The steps are preferably performed by the processing means, processor, or computer in cooperation with physical means, such as those described with reference to any of the disclosed embodiments, with aid of e.g. an illumination control circuit powering the light source(s) of the array. The computer program preferably comprises program code, as illustrated in FIG. 8 , which is stored on a computer readable medium 602 , which can be loaded and executed by a processing means, processor, or computer 604 to cause it to perform the method according to the present invention, preferably as any of the exemplary embodiments described with reference to the drawings. The computer program can for example cause the processor to correct calculated trajectories to account for windage etc, or the compensated position for the reticle resulting from a tilt of the fire-control system.
The computer and computer program can be arranged to execute the program code sequentially where actions of the any of the methods are performed stepwise, or be arranged to execute the program code on a real-time basis where actions of any of the methods are performed upon need and availability of data. The processing means, processor, or computer is preferably what normally is referred to as an embedded system. Thus, the depicted computer readable medium 602 and computer 604 in FIG. 8 should be construed to be for illustrative purposes only to provide understanding of the principle, and not to be construed as any direct illustration of the elements.
The present invention is particularly well suited for weapons firing ammunition with a high trajectory, such as an underslung grenade launcher (UGL), automatic grenade launcher (AGL), recoilless grenade rifle (such as the Carl Gustaf), etc, and may to the full extent be used on such a weapon. | A fire-control system including a housing and a light channel, through which a user may directly observe a target and receive visually displayed information simultaneously. The light channel includes partially reflective optics. The fire-control system also includes a light source for visualization of a reticle to the user via the partially reflective optics and means for receiving a measure of the distance to the target. The fire-control system further includes a processor for determining the adequate position of the reticle based on the distance to the target and for controlling the light source to emit light so that the reticle is visualized at the adequate position. The light source is an array capable of selectively emitting light in well-defined locations on its surface. | 5 |
BACKGROUND OF THE INVENTION
Enzyme-catalyzed reactions often have the advantages of proceeding with great chemical specificity under relatively mild conditions, and often accomplish what man finds difficult, if not impossible, to duplicate in the laboratory. For such reasons there is increasing emphasis on the use of enzymatic processes on a commercial scale. One example, of many which could be cited, is the conversion of glucose to fructose using glucose isomerase.
Enzymes are water soluble, and if they are merely used in aqueous solutions recovery of enzyme for reuse is difficult and expensive. Using the enzyme only once affords a process which is relatively expensive. Consequently, many techniques have been developed for immobilizing the enzyme in such a way that substantial enzymatic activity is displayed while the enzyme itself remains rigidly attached to some water-insoluble support, thereby permitting reuse of the enzyme over substantial periods of time and for substantial amounts of feedstock. One illustration of a method for immobilizing an enzyme is found in Levy and Fusee, U.S. Pat. No. 4,141,857, where a polyamine is adsorbed on a metal oxide such as alumina, treated with an excess of a bifunctional reagent, such as glutaraldehyde, so as to cross-link the amine, thereby entrapping the resulting polymer in the pores of the metal oxide, and then contacting the mass with enzyme to form covalent bonds between the pendant aldehyde groups and an amino group on the enzyme.
The useful life of an immobilized enzyme system is limited by a continual decrease in enzymatic activity. Among the many mechanisms which lead to enzyme deactivation in such systems are: poisoning of the enzymes by impurities in the feedstock; other chemical modification of the enzyme; denaturation of the enzyme; rupture of the bond between the pendant group and the enzyme leading to dissolution of the enzyme; cleavage of the bond between the pendant group and the intermediate binding layer; loss of the binding layer as, for example, by physical ablation or cleavage of the chemical bond which hold it to the support.
Whatever the mechanism of the enzyme deactivation, reactivation of a deactivated immobilized enzyme system would prove to be a substantial advance in the art as well as being economically highly desirable. At least conceptually, two distinct approaches to reactivation are possible. One mode would be to rejuvenate the enzyme itself, i.e., assuming no physical loss of enzyme the transformations which rendered it inactive would be reversed and the enzyme would revert to its initial active state. The alternative is to restore the immobilized enzyme system to that state initially present immediately prior to attachement of enzyme, so that it would be capable of binding fresh, active enzyme once again. This invention relates to the latter approach.
SUMMARY OF THE INVENTION
An object of this invention is to regenerate an immobilized enzyme system which has become substantially deactivated. An embodiment of this invention resides in a process for regenerating an immobilized enzyme system comprising treating the system with a base as an enzyme stripping agent, removing the base, treating the system with a bifunctional organic molecule which serves as a pendant group, and removing the excess of bifunctional organic molecule, so as to put the system in a state where fresh, active enzyme can be immobilized by suitable means. A more specific embodiment of this invention resides in the application of this process to a system wherein the binding layer is an organic polymeric material and the pendant functional moiety can bond covalently with an enzyme without greatly destroying its activity. Another more specific embodiment of this invention is the application of this process wherein the enzyme is glucose isomerase and the stripping agent is an alkali metal hydroxide, such as sodium hydroxide and potassium hydroxide. Other objects and embodiments will be apparent from the description provided herein.
It is to be emphasized again that enzymes are merely representative of one class of reactive chemical entities which may be immobilized to act in some chemical process. Therefore, this invention encompasses regeneration of any immobilized reactive chemical entity which has become substantially deactivated.
DESCRIPTION OF THE FIGURE
Many immobilized enzyme systems, such as that described above, have a common conceptual basis which is depicted pictorially in the FIGURE. It is to be understood that enzymes are merely one class of reactive chemical entities which may be immobilized and subsequently utilized in a chemical process.
There is a central core support, A, whose primary purpose is to provide mechanical and thermal stability to the system and which is chemically inert in the enzymatic reaction. The intermediate primary layer, B, provides an interface between the core and the pendant groups, C. This layer may be held to the core either by physical entrapment, as within the pores of A, by strong short-range physical and/or chemical forces, as by surface adsorption or absorption, or by chemical binding to the surface of the core support. The pendant groups, C, may be part of the molecular structure of the binding layer, or may be chemically bonded to a suitable site on the binding layer. Such pendant groups are characterized by the presence of a chemically reactive functionality, usually terminally situated, which can covalently bond to some part of the enzyme, or other reactive chemical entity, sufficiently removed from its "active site" so as not to interfere substantially with its catalytic activity.
DESCRIPTION OF THE INVENTION
Although several kinds of immobilized enzyme systems are available, those wherein the enzyme is covalently bonded to a support seem to offer the best compromise between enzyme availability to feedstock and long-term immobility on a supporting structure. Accordingly, emphasis is placed on stripping deactivated enzyme and regenerating an active immobilized enzyme in such a system. This invention relates to the structure depicted in the Figure. The central core support, A in the figure, may be a metal oxide, preferably alumina and silica, glass, a ceramic or a metal. It needs to provide structural integrity, especially mechanical strength, have good characteristics in a system where there is a liquid flow, and provide a surface, wholly or in part, to which a layer of organic material can be attached either by physical or chemical means, or by a combination of the latter.
The binding layer, B, may be an organic polymer or a resin. Examples of such binding layers include functionalized polyethylenes, polyamines cross-linked with agents such as dialdehydes and diisocyanates, and others known to those skilled in the art. In a preferred embodiment, the binding layer is a polyamine such as polyethyleneimine, tetraethylenepentamine, ethylenediamine, diethylenetriamine, triethylenetetramine, pentaethylenehexamine, hexamethylenediamine, phenylenediamine, and the like, cross-linked via a reagent selected from the group consisting of dialdehydes and the diisocyanates, as for example glutaraldehyde, succindialdehyde, toluenediisocyanate, and the like. In another preferred embodiment the binding layer is a functionalized polystyrene, such as aminopolystyrene, cross-linked by one of the aforementioned reagents.
The pendant group, C, may be an independently functionalized group of the polymer, as for example an aldehydic moiety attached via mediating carbon atoms to a polyethylene chain, an independently functionalized group of a resin, or an unreacted terminus of the cross-linking agent wherein the other terminus is covalently bonded to the binding layer. In a preferred embodiment, the pendant group arises from a cross-linking agent selected from the group consisting of dialdehydes and diisocyanates.
In some instances the demarcation between core support, A, binding layer B, and pendant group C may seem indistinct. For example, the binding layer may appear to be part of the core, and might even contain a functional group which can covalently bond to an enzyme, thereby providing an immobilized enzyme system. A representative of this class is a chemically modified glass whose surface bears an organic residue having a functional group capable of covalently bonding to an enzyme. This invention relates to such a system, and to all systems which are functionally equivalent to, or can be functionally described by, the representation in the figure, however that may be attained in any particular immobilized enzyme system. The combination of structures A, B and C forms a support system; addition of enzyme forms an immobilized enzyme system.
The method of stripping and regeneration taught herein may be applied to any reactive molecule which can react with the pendant functional group without substantial loss of chemical activity; enzymes form an important class of such reactive molecules. Examples of such enzymes include glucose isomerase, glucose amylase, lactase, cellulase, glucose oxidase, trypsin, papain, hexokinase, chymotrypsin, acylase, invertase, protease, pepsin, rennin, xylanase, etc. It is to be understood that these enzymes are cited solely for illustrative purposes and it is not to be construed as a limitation of this invention. Other enzymes may be utilized, but not necessarily with equivalent results.
The physical form of the immobilized enzyme system generally is determined by factors extraneous to the stripping-regeneration process. Thus, the system may be in the form of pellets of, for example, 1/16 inch size, or it may be in the form of smaller spheres of, for example, 60-80 mesh. Although the form in which the immobilized enzyme system is used may necessitate different optimum parameters in the stripping-regeneration process, the basic method remains unchanged.
Immobilized enzyme systems in which the enzyme has become totally inactive, or nearly so, may be unpacked from the columns where they had been used and placed in containers. To this may be added sufficient enzyme stripping reagent such that the pellets or spheres are completely covered with liquid. Among the stripping reagents which are suitable for use are alkaline materials. Examples of such reagents include the alkali metal hydroxides and carbonates, such as those of lithium, sodium, potassium, cesium and rubidium, ammonia, ammonium carbonate, quaternary ammonium hydroxides such as tetramethylammonium hydroxide, benzyltrimethylammonium hydroxide, cetylpyridinium hydroxide, etc. The concentration of the reagent and amount used are not critical, provided that there is sufficient reagent to remove all inactive enzyme, and that the volume is sufficient to provide adequate contact with the pellets or spheres. Concentrations of base employed may range from about 0.01 to about 5 molar. The temperature at which stripping is conducted may be from about 20° C. to about 75° C., preferably from about 50° C. to about 70° C. Contact time may be from about 1 to about 30 minutes, preferably from about 1 to about 10 minutes, and may be accompanied by agitation. In one embodiment, the reagent is sodium hydroxide.
After the material has been treated with the base for an appropriate time, excess reagent may be removed by decantation. The pellets or spheres are then washed thoroughly with water to remove any base adhering to the surface. When no more base is present the system is ready for contacting with a solution which furnishes the pendant group. For example, the solution may be one of glutaraldehyde in water, where the concentration of glutaraldehyde is not material so long as there is present sufficient material to replace any pendant groups lost in its prior history. Where the pendant group is reactive toward water, the enzyme support system may have to be dried, by means which will be obvious to those skilled in the art, prior to treatment with the reagent. Although the system generally will be treated with a solution which furnishes the pendant group originally present, it may be treated with a solution which furnishes a different pendant group. Representatives of materials furnishing a pendant group enumerated solely for the purpose of illustration, include glutaraldehyde, succindialdehyde, terepthaladehyde, and toluenediisocyanate.
When the enzyme support system has been contacted with a solution furnishing the pendant groups for a time sufficient to replace all those previously lost, which time may vary from about 30 minutes to about 5 hours, depending on the nature of the support system, its history, the stripping reagent used and the nature of the pendant group, it is washed thoroughly to remove unreacted but adhering molecules which furnish the pendant group. At this stage the support system is rejuvenated, which is to say that it approximates its condition prior to initial enzyme immobilization. The support system is now ready to accept fresh, active enzyme to regenerate an immobilized enzyme system whose activity approximates that obtained with a new support. In the case, for example, of a polyethyleneimine binding layer cross-linked with excess glutaraldehyde, glucose isomerase may be immobilized by contacting the support system, with agitation, with an aqueous solution of the enzyme for 2 to 24 hours at a temperature from about 0° to about 50° C. preferably from about 0° to about 10° C. However, it is not an object of this invention to teach how enzymes are best immobilized given a particular support, thus it suffices to say that the support regenerated by the method of this invention is treated with enzyme in whatever way is appropriate for immobilization of that particular enzyme on a particular support system.
The description above is for a stripping-regeneration process run in a batchwise method. However, the process of this invention may be done in a continuous manner where such a mode is advantageous. Thus, as an example where the stripping agent is potassium carbonate and the reagent furnishing the pendant group is glutaraldehyde, the deactivated immobilized enzyme system in a column may be treated with a potassium carbonate solution recirculated or passed through the column for a time sufficient to remove all enzyme. Thereafter the column may be washed with water until all traces of alkaline material are removed, followed by treatment with recirculated glutaraldehyde solution until there is no further uptake of the latter reagent. Unreacted but adhering glutaraldehyde may be removed by treatment with fresh water, after which active enzyme may be immobilized by suitable means.
Whether the stripping portion of the process of this invention consists of selective removal of spent enzyme from the pendant group, or whether it consists of removal of the pendant group from the binding layer, or some combination thereof, is not known. This invention is meant to encompass removal of spent enzyme from an enzyme support system of the type described herein whatever the mechanism of removal.
The following examples serve merely to illustrate the process of this invention, and it is to be understood that this invention is not limited thereto.
EXAMPLE 1
An immobilized enzyme system based on polyethyleneimine (PEI) on alumina cross-linked with glutaraldehyde and bearing glucose isomerase had an initial activity of 1400 units per gram. The bed, composed of 60-80 mesh particles, was treated with 2 M NaOH in an amount of 20 ml solution of base per gram of bed material. This mixture was heated with stirring at 60° F. for 5 minutes, after which the solution was removed by decantation. The solid was then stirred with water sufficient to cover all material present and liquid was decanted. This washing procedure was repeated until the wash liquid was neutral (pH 7). At this stage the material displayed no enzymatic activity. Regeneration was accomplished by adding a 2.5% aqueous solution of glutaraldehyde in an amount equal to 18 ml. per gram of bed for about one hour. Excess glutaraldehyde was removed by thorough washing with water. A preparation of fresh, active glucose isomerase was contacted with the regenerated support system for 18 hours at 4° C. with continual shaking. The immobilized enzyme system was thoroughly washed with water to remove adhering but mobile enzyme. The resulting immobilized enzyme system had a glucose isomerase activity of 820 units per gram, or 59% of the activity originally present.
EXAMPLE 2
The immobilized enzyme system was like that of Example 1 but in 1/16" pellets. Its initial activity was 141 units per gram of bed. Deactivated bed material was treated with sodium hydroxide using the procedure given in Example 1. After reimmobilization of glucose isomerase the system showed a glucose isomerase activity of 121 units per gram, or 86% that originally present. | A method for regenerating an immobilized enzyme system comprises treating the deactivated system with a base, removing excess base, treating the system with a bifunctional organic reagent which furnishes a pendant group, removing excess of said bifunctional reagent, and immobilizing fresh, active enzyme. | 2 |
BACKGROUND OF THE INVENTION
In the case of motor vehicles with internal combustion engines, ever stricter exhaust emissions limits mean that air pollutants, such as nitrogen oxides (NOx), in the exhaust gas flow must be reduced to a greater and greater extent. One known method which is used in this context is catalytic reduction (known as “Selective Catalytic Reduction” or SCR). In this case, a reductant is pumped out of a tank as far as a metering module in the region of the exhaust line by means of a pump. The metering module required to inject the reductant is arranged within the exhaust line, generally ahead of the catalyst in which the reduction of nitrogen oxides takes place. A 32.5% aqueous urea solution (known as “AdBlue®”) is generally used as a reductant. In many cases, diaphragm pumps are used to deliver the reductant, and these generally have a preferred direction of delivery.
In many cases, the diaphragm pumps are driven by means of an electric motor having an eccentric connected by a connecting rod to the pump diaphragm. If the eccentric is set in rotation with the aid of the electric motor, the pump diaphragm is periodically raised and lowered by the connecting rod, with the result that the reductant is drawn in from the storage tank and pumped as far as the metering module. An orifice or restrictor arranged downstream of the diaphragm pump prevents a pressure rise in the system when the metering module is closed or is delivering only a very small quantity of the reductant into the exhaust line. For this purpose, the delivered quantity that is not required is directed back into the storage tank by the orifice via an additional return line. The exhaust gas aftertreatment system furthermore has a complex open-loop and/or closed-loop control device for controlling all the system processes and a large number of sensors and actuators, which are interconnected via a bidirectional bus system.
The aqueous urea solution freezes below −11° C. In order to ensure the required ice pressure resistance after the internal combustion engine is switched off, the reductant must as far as possible be sucked back completely out of all regions which are exposed over a prolonged period to a temperature of −11° C. or less. In order to be able to implement the suck-back process by means of the diaphragm pumps which are conventionally employed, a separate 4/2-way valve is generally used.
In normal delivery mode, in particular during the normal operation of the internal combustion engine, the 4/2-way valve is in the deenergized idle state, allowing the reductant to be pumped out of the tank with the aid of the diaphragm pump and reach the metering module via the 4/2-way valve. While the reductant is being sucked back out of the exhaust gas aftertreatment system, the delivery direction of the diaphragm pump can be maintained unaltered. Only the 4/2-way valve is activated. In normal delivery mode, the reductant flows in opposite directions through two parallel ducts in the 4/2-way valve while, in suck-back mode, the reductant flows in opposite directions through two further, intersecting ducts in the 4/2-way valve.
However, multi-way valves of this kind involve a construction of complex design and are therefore also expensive to produce. Moreover, such valves are prone to leaks, are susceptible to wear and require a lot of maintenance.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide a pumping device for exhaust gas aftertreatment systems, in particular those operating by the “SCR” method, which has little tendency to wear, has a high degree of fail safety and furthermore requires little maintenance.
A pumping device for supplying an exhaust gas aftertreatment system of an internal combustion engine with a reductant, in particular with an aqueous urea solution, in order to reduce nitrogen oxides in the exhaust gas flow of the internal combustion engine is disclosed, having a motor for driving two pumps.
According to the invention, the first pump is connected to the motor by means of a first coupling, and the second pump is connected to the motor by means of a second coupling.
The couplings are preferably designed as freewheel couplings but, as an alternative, can also be embodied as switchable (releasable) couplings. It is thereby possible in a simple way selectively to connect the first pump (suck-back pump) or the second pump (delivery pump) to the drive motor and thus to switch from what is referred to as a normal “delivery state” while the internal combustion engine is running to what is known as a “suck-back state”, in particular after a relatively long stoppage time of the internal combustion engine. The required ice pressure resistance at ambient temperatures of −11° C. or below is achieved by means of the, ideally complete, sucking back of the reductant out of the exhaust gas aftertreatment system in order to prepare for a relatively long stoppage time of the internal combustion engine.
In the preferred embodiment of the pumping device, the couplings are freewheel couplings acting in opposite directions.
It is thereby possible to switch from the “delivery state” to the “suck-back state” and vice versa by simply reversing the direction of rotation of the motor. When the motor is stationary, neither of the two pumps is driven—irrespective of the switching state of the couplings—and therefore the pumping device is in what is known as the “idle state”. Each of the pumps connected for operation in opposite directions is therefore only ever operated in the delivery direction thereof, irrespective of the system state (“delivery state”/“suck-back state”).
Another advantageous embodiment of the pumping device envisages that a metering module of the exhaust gas aftertreatment system is connected to a discharge line of the second pump and to a suction line of the first pump by means of a shuttle valve. The metering module is used to inject a precisely determined quantity of the reductant into an exhaust pipe containing a catalyst for reducing the nitrogen oxides. It is in the catalyst that the actual selective chemical reduction of nitrogen oxides in the exhaust gas flow of the internal combustion engine to water (H 2 O) and nitrogen (N 2 ) takes place. The shuttle valve allows an effective hydraulic separation between the two pumps, with the shuttle valve being switched over automatically simply by the pressure conditions prevailing at a pressure port and a suction port of the shuttle valve. The filter unit and the metering module arranged downstream thereof are connected to the shuttle valve via a third port of the shuttle valve, through which the reductant flows in both directions (bidirectional port).
In a preferred embodiment, a suction line of the second pump and a discharge line of the first pump are connected to a storage tank for the reductant.
Owing to this arrangement of the lines, the reductant can be drawn in from the storage tank by means of the second pump during the normal operation of the internal combustion engine and pumped onward at excess pressure as far as the metering module via the shuttle valve. In addition, this line routing enables the reductant to be sucked back out of the metering module via the shuttle valve as far as the storage tank by means of the first pump in order to initiate a relatively long stoppage time of the internal combustion engine.
Another advantageous embodiment of the pumping device envisages that both pumps are designed as diaphragm pumps.
The diaphragm pumps make possible a pumping device construction of simple design. Moreover, diaphragm pumps have good corrosion resistance since the pumping space is separated completely from the drive zone by the diaphragm. The use of diaphragm pumps increases the operational reliability of the pumping device for the reductant, which is generally chemically aggressive, and, at the same time, considerably reduces the outlay on maintenance. In general, diaphragm pumps allow virtually maintenance-free operation for the entire life of a motor vehicle.
According to another advantageous embodiment, it is envisaged that an electric motor, in particular an external rotor motor, is used to drive the pumps.
First of all, the embodiment of the motor as an electric motor has the advantage of ease of closed-loop and/or open-loop control. Moreover, the use of an external rotor motor has the advantage that the delivery flow can be made more uniform through the high moment of inertia of the rotor rotating around the stator.
According to another advantageous development of the pumping device, at least one return flow restrictor is provided.
Particularly where use is made of an external rotor motor, the rotating rotor of which generally has a high moment of inertia, the motor remains continuously switched on in the “delivery state” in order to ensure as a uniform a delivery flow is possible and to minimize the run-up times of the motor. Moreover, a motor which is permanently switched on allows a uniform delivery flow, thereby ensuring a reliable and continuous supply of the reductant to the metering module. However, continuous operation of the motor and of the associated second pump in the “delivery state” can lead to an unwanted pressure increase in the region of the discharge line between the second pump, the shuttle valve and the metering module if too little or no reductant is discharged by the metering module. In order to avoid such a pressure rise, a return flow restrictor or a return flow orifice can preferably be provided in the discharge line between the second pump and the shuttle valve, directing the excess reductant that is not required by the metering module back to the storage tank via an additional return flow line.
In an alternative embodiment, the return flow restrictor can be an integral part of the shuttle valve. In general, a restrictor or an orifice with a cylindrical bore and a small cross-sectional area is implemented technically.
In addition, a method, in particular for operating a pumping device of this kind, for supplying an exhaust gas aftertreatment system of an internal combustion engine with a reductant, in particular with an aqueous urea solution, in order to reduce nitrogen oxides in the exhaust gas flow of the internal combustion engine, is disclosed, having a motor for driving two pumps.
According to the method, a switch is made between a “delivery state” and a “suck-back state” by reversing the direction of rotation of the motor, wherein, in the delivery state, the reductant is pumped out of a storage tank for the reductant, via a shuttle valve, as far as a metering module by means of the second pump and, in the “suck-back state”, the reductant is sucked back out of the metering module, via the shuttle valve, into the storage tank by means of the first pump.
Simply by changing the direction of rotation of the motor, the method allows a quick change between the “delivery state”, in which the metering module of the exhaust gas aftertreatment system is supplied with the reductant, and the “suck-back state”, in which the reductant contained in the exhaust gas aftertreatment system is returned almost completely to the storage tank in order to achieve the required ice pressure resistance in the case of relatively long stoppage times. After the motor has been switched off, the system is in an “idle state”, in which there is no delivery of the reductant.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail below by means of the drawings, in which:
FIG. 1 shows a schematic illustration intended to elucidate the fundamental principle of operation of the pumping device;
FIG. 2 shows a diagrammatic illustration of the drive motor with two freewheel couplings and the associated two pumps;
FIG. 3 shows a cross section through the shuttle valve, and
FIG. 4 shows a perspective view of the closing member of the shuttle valve.
DETAILED DESCRIPTION
FIG. 1 shows a schematic illustration intended to elucidate the fundamental principle of operation of the pumping device for an exhaust gas aftertreatment system operating by what is known as the “SCR” method.
Among the components of the exhaust gas aftertreatment system 10 are a storage tank 12 for the reductant 14 , at least one filter unit 16 and a metering module 18 .
For greater clarity, the exhaust line of the internal combustion engine, the catalyst required within the exhaust line for catalytic reduction, an open-loop and/or closed-loop control device required to control all the processes within the exhaust gas aftertreatment system 10 , and a large number of sensors and actuators which communicate with the open-loop and/or closed-loop control device via a bidirectional bus system are not shown in FIG. 1 .
The fundamental directions of flow of the reductant 14 within the exhaust gas aftertreatment system 10 are illustrated by white arrows, which are not provided with reference numerals. Among the components of a pumping device 20 designed in accordance with the invention for supplying the exhaust gas aftertreatment system 10 with the reductant 14 are a first pump 22 (suck-back pump) and a second pump 24 (delivery pump). The pumps 22 , 24 are each connected mechanically, via the freewheel couplings 26 , 28 , to a motor shaft 30 of a (drive) motor 32 . In a preferred embodiment, the motor 32 is designed as an electric external rotor motor. The (continuous) motor shaft 30 allows simultaneous driving of both freewheel couplings 26 , 28 , which are designed to act in opposite directions according to the invention.
This means that only the second pump 24 is driven when the motor 32 rotates clockwise (“R”), for example, while the first freewheel coupling 26 freewheels in this direction of rotation and consequently the first pump 22 is stationary. If the direction of rotation of the motor 32 is reversed, so that it then rotates counterclockwise (“L”), the second freewheel coupling 28 freewheels instead. As a result, the second pump 24 is stationary, and the first pump 22 is then driven via the first freewheel coupling 26 , which is in engagement in the direction of rotation (“L”). The two oppositely acting freewheel couplings 26 , 28 thus allow alternating operation of the pumps 22 , 24 , depending on the direction of rotation of the motor 32 and of the motor shaft 30 .
A discharge line 34 of the second pump 24 is connected to a shuttle valve 36 , which is in the no-load idle position in the illustration in FIG. 1 . In a corresponding manner, a suction line 38 of the first pump 22 is likewise connected to the shuttle valve 36 . The shuttle valve 36 is connected hydraulically, via lines that are not designated, to the filter unit 16 and to the metering module 18 of the exhaust gas aftertreatment system 10 . In the context of this description, the term “lines” is taken to mean both pipes and flexible hoses, including armored hoses. The directions of delivery of the two pumps 22 , 24 , which are preferably designed as diaphragm pumps, are designed to be opposite one another. Consequently, the second pump 24 always draws in the reductant 14 from the storage tank via a suction line 40 , while the first delivery pump 22 always pumps the reductant 14 back into the storage tank 14 via a discharge line 42 .
An illustrative sequence of the method during the operation of the pumping device 20 and, in association therewith, further details of the construction of the pumping device 20 will be explained in detail below:
When the internal combustion engine is running or has just been started, the reductant 14 is drawn in from the storage tank 12 by the second pump 24 and passes via the discharge line 34 into the shuttle valve 36 (“delivery state”). Owing to the delivery pressure built up in this way, a closing member 44 , illustrated here schematically as a ball, rises from the right-hand valve seat 46 of the shuttle valve 36 counter to the spring force built up by the undesignated spring, and—counter to the spring force thereof—is pressed against the left-hand valve seat 48 . As a result, the reductant 14 can flow through the shuttle valve 36 and passes via the filter unit to the metering module 18 . During this process, the motor 32 , which is rotating clockwise (“R”), drives the second pump 24 via the motor shaft 30 and the second freewheel coupling 28 . Control of the speed and direction of rotation of the motor 32 is performed by means of the open-loop or closed-loop control device mentioned at the outset.
An electric motor, designed, in particular, as an “external rotor”, is preferably used as a motor 32 . Using an electric motor makes it easy to perform open-loop and/or closed-loop control. Since, by virtue of its design, the rotor rotates around the stator in the case of an external rotor, the higher moment of inertia of the motor 32 due to this fact can be used in an advantageous manner, in particular to make the delivery flows of the pumps 22 , 24 more uniform. Owing to the high moment of inertia of the motor 32 , however, it is advantageous to make the motor 32 run as continuously as possible, both in the “delivery state” and in the “suck-back state” of the reductant 14 , in order to avoid relatively long run-up times before a target motor speed is reached. After the suck-back process is fully ended, the motor 32 can be switched off. Owing to the fact that the motor 32 usually runs continuously, a particularly uniform supply of reductant 14 to the metering module 18 is furthermore obtained.
Particularly in the “delivery state”, however, there can be an unwanted pressure increase in the region of the discharge line 34 , the shuttle valve 36 , the downstream filter unit 16 and/or the metering module 18 in this case. In order to prevent this, the pumping device 20 in the embodiment shown is fitted with a return flow restrictor 50 or a return flow orifice. Here, the return flow restrictor 50 is connected to the discharge line 34 . Excess reductant 14 which is not required in the metering module 18 can then flow back into the storage tank 12 via the return flow restrictor 50 and a return flow line 52 arranged downstream thereof. It is thereby possible to prevent the unwanted pressure increase. As an alternative, it is possible (cf, especially, FIGS. 3 and 4 ) to design the return flow restrictor 50 or the return flow orifice as an integral part of the shuttle valve 36 , thereby enabling the number of line connections, sealing locations and system components to be reduced. To prepare for a relatively long stoppage time of the internal combustion engine, the reductant 14 is sucked back into the storage tank 12 . For this suck-back process, the direction of rotation of the motor 32 is reversed from clockwise (“R”) to counterclockwise (“L”), thereby initiating what is known as the “suck-back state”. Owing to the reversal in the direction of rotation, the second freewheel coupling 28 is in the freewheeling state, with the result that the second pump 24 is stationary. In contrast, the first pump 22 is set in motion by means of the first freewheel coupling 26 , which is in engagement in this direction of rotation. As a result, the reductant 14 is drawn in by the first pump 22 from the metering module 18 , via the filter unit 16 and the shuttle valve 36 , via the suction line 38 , and is pumped back into the storage tank 12 by means of the discharge line 42 . This “suck-back state” is maintained until, in the ideal case, all the reductant 14 has been sucked back out of the exhaust gas aftertreatment system 10 , thus establishing the required ice pressure resistance. Once the suck-back process is complete, the motor 32 can be switched off, with the result that both pumps 22 , 24 stop and the pumping device 20 is in the “idle state”.
In the “suck-back state”, the closing member 44 of the shuttle valve 36 is pressed firmly against the right-hand valve seat 46 owing to the action of the undesignated compression spring, and, at the same time, the left-hand valve seat 48 is exposed, allowing the reductant 14 to be drawn in by the first pump 22 against only a slight resistance. The shuttle valve 36 thus ensures effective hydraulic separation between the two pumps 22 , 24 and the delivery branches connected thereto in both main states of the pumping device 20 in the form of the “delivery state” and the “suck-back state”.
The shuttle valve 36 operates automatically since a pressure of up to 5.0 bar built up in the discharge line 34 by the second pump 24 in the “delivery state” is significantly higher in the discharge line 34 than a suction vacuum of about 0.5 bar brought about by the first pump 22 in the region of the suction line 38 . Consequently, the shuttle valve 36 responds solely on the basis of the respective pressure conditions in the region of the discharge line 34 and of the suction line 38 .
If the internal combustion engine is to be restarted, the “delivery state” is initiated again, starting from the “idle state”, in that the motor 32 runs up in the clockwise direction of rotation “R”, with the result that the second delivery pump 24 pumps the reductant 14 out of the storage tank 12 as far as the metering module 18 . The cyclical change between the “delivery state”, the “suck-back state” and the “idle state” can be performed as often as required.
Instead of the two freewheel couplings 26 , 28 in the preferred embodiment, it is also possible to use couplings (not shown) that can be switched electromagnetically, for example, or in some other way, these being addressed by the open-loop and/or closed-loop control device in a controlled manner. In such a configuration, it is also possible to make both pumps 22 , 24 deliver simultaneously if the metering module 18 is taking off too little reductant 14 , such that the excess reductant 14 is pumped back immediately into the storage tank 12 by means of the first pump 22 (“recirculation”). It is thereby possible to avoid a pressure rise while the motor 32 is running. In certain circumstances, this may make the return flow restrictor 50 or the return flow line 52 superfluous. In such an embodiment, the shuttle valve 36 may also be unnecessary if the two pumps 22 , 24 are sufficiently pressure-resistant or secure against throughflow on both sides when stationary, such that they themselves act as closed “valves” when stationary. Consequently, it may be necessary to form the pumps 22 , 24 with some other type of pump than the diaphragm pump that is used for preference here.
FIG. 2 illustrates a sectional view of a possible illustrative embodiment of the motor having two freewheel couplings and associated (diaphragm) pumps.
The motor 32 , which is preferably designed as an external rotor, is flanged to a housing 60 . The power supply to the motor 32 is via a plug connection 62 or a plug connector. The first and second freewheel couplings 26 , 28 are firmly connected to the motor shaft 32 and are driven by the latter. The freewheel couplings 26 , 28 are connected to two eccentrics 64 , 66 , on each of which a ball bearing 68 , 70 is mounted. Two connecting rods 72 , 74 , to each of which a pump diaphragm 76 , 78 is pivotally attached, are rotatably mounted on the ball bearings 68 , 70 .
By means of the two eccentrics 64 , 66 and the connecting rods 72 , 74 , the rotary motion of the motor shaft 30 is transformed into a linear motion, which is transmitted to the diaphragms 76 , 78 of the pumps 22 , 24 by the connecting rods 72 , 74 . As a result, the diaphragms 76 , 78 perform a periodic upward and downward motion, parallel to the two undesignated white arrows, and pump the reductant through the pumping device 20 —as explained in greater detail as part of the description of FIG. 1 . Owing to the opposite action of the two freewheel couplings 26 , 28 , only that pump of the two pumps 22 , 24 is in delivery mode, of which the freewheel coupling 26 , 28 is in engagement—depending on the direction of rotation of the motor 32 . Any check valves that are still required for the delivery mode of the pumps 22 , 24 are not shown in FIG. 2 .
FIG. 3 illustrates a more detailed cross section through one embodiment of the shuttle valve 36 in a no-load “idle position”.
The fundamental flow conditions of the reductant through the shuttle valve 36 are once again illustrated by the three undesignated white arrows. Among the components of the shuttle valve 36 is a housing 80 , in which an approximately cup-shaped closing member 82 is accommodated in a sprung manner in such a way that it can be moved parallel to a vertical longitudinal axis 84 . The closing member 82 has an encircling projection 86 with a first seal 88 (sealing lip), which is pressed against a right-hand housing wall 92 as a sealing surface owing to the action of a compression spring 90 . A right-hand pressure port 94 of the shuttle valve 36 is thereby sealed off, said port normally being connected to the discharge line 34 of the second pump 24 (cf FIG. 1 ).
If the pressure of the reductant in the region of the pressure port 94 rises due to a pumping action of the second pump 24 to such an extent that the spring force of the compression spring 90 is overcome, the closing member 82 moves to the left, parallel to the valve longitudinal axis 84 , until a second seal 96 (sealing lip) rests against a left-hand housing wall 98 as a sealing surface. The first seal 88 is situated on an undesignated front side of the projection 86 or of the closing member 82 , while the second seal 96 is situated on an undesignated rear side of the projection 86 .
In this “open position” of the closing member 82 , the reductant can flow from the pressure port 94 , through a large, approximately cylindrical chamber 100 within the housing 80 , as far as a bidirectional port 102 , which is generally connected to the filter unit 16 or the downstream metering module 18 . In order to ensure proper functioning of the shuttle valve 36 , the compression spring 90 should have a spring force sufficient to ensure that the movement of the closing member 82 to the left takes place at the earliest from a pressure of 1.5 bar in the region of the pressure port 94 .
If the pump 24 ceases delivery, then, after a sufficient pressure drop, the closing member 82 is once again pushed to the right by the spring force of the compression spring 90 until seal 88 is resting against the right-hand housing wall 92 as a sealing seat, and the “idle position” shown in FIG. 3 has been reached again.
In the “suck-back state”, the closing member 82 is in the “idle position” shown in FIG. 3 , allowing the reductant to flow into the large chamber 100 from above through the (bidirectional) port 102 . From there, the reductant flows via a multiplicity of suck-back bores—of which just one suck-back bore 104 is designated—into a hollow-cylindrical stem 106 of the closing member 82 . From there, the reductant flows into a smaller, cylindrical chamber 108 of the housing 80 , which opens into a suction port 110 . The suction port 110 is generally connected to the first pump 22 , which is used to pump the reductant back into the storage tank (cf FIG. 1 ).
In the embodiment shown in FIG. 3 , the shuttle valve 36 furthermore also performs the function of a return flow restrictor or a return flow line (cf FIG. 1 ) in the pumping device, which can be eliminated as a result.
For this purpose, an orifice opening 114 with a small cross-sectional area is introduced into a base 112 of the closing member 82 , forming a return flow restrictor or return flow orifice in terms of hydraulics. By means of the orifice opening 114 , which is formed by a conically countersunk but otherwise cylindrical bore, excess reducing fluid which is not discharged in the metering module owing, for example, to special operating states of the internal combustion engine, can return from the pressure port 94 , via the suction port 110 , to the storage tank 12 through the first pump. As a result, an excessive pressure rise in the system is avoided. The two seals 88 , 96 are produced from an elastomer which is sufficiently resistant to chemicals, especially to the reductant (“AdBlue®”), such as an EPDM (ethylene-propylene-diene monomer). In principle, the closing member 82 or the projection 86 can be produced from a metal alloy or from a plastic material as long as the required resistance to the reductant is ensured. In a preferred embodiment, however, the closing member 82 is produced from a thermoplastic or a thermosetting plastic (“TP”/“TS”), the thermosetting plastic being preferred in the case of the integrated throttling function in FIG. 3 since this is more resistant to “flow abrasion”, which occurs to a greater extent as compared with that in the orifice opening 114 . The seals 88 , 96 can be formed integrally with the closing member 82 by what is known as the “2-C” injection molding method (“two-component” injection molding method), for example, or by way of what is known as the “compression molding method”.
FIG. 4 shows an enlarged perspective view of the closing member 82 from FIG. 3 .
A multiplicity of suck-back bores are introduced at uniform spacings around the circumference in the sleeve-type stem 106 of the closing member 82 , one of said suck-back bores bearing the reference numeral 104 . The compression spring 90 is inserted into the stem 106 and is guided radially by the latter. The first and second seals 88 , 96 are arranged above and below the encircling projection 86 . In the event that the closing member 82 is formed by a plastic material, the two seals 88 , 96 can be produced integrally (in one piece) with the body of the closing member 82 by the two-component injection molding method (known as the “2-C” injection molding method), for example, or by what is known as the “compression molding method”.
The pumping device according to the invention for an exhaust gas aftertreatment system in a motor vehicle, having two pumps and a drive motor, which are each alternately driven by the drive motor via oppositely acting freewheel couplings in the preferred embodiment, allows a reliable and uniform supply of the reductant required for catalytic exhaust gas purification to a metering module of the exhaust gas aftertreatment system.
Moreover, the pumping device allows reliable and yet low-maintenance operation of the exhaust gas aftertreatment system in comparison with previously known solutions having a 4/2-way valve, and the optimized suck-back process furthermore ensures the required ice pressure resistance at low motor vehicle operating temperatures. | The invention relates to a pumping device ( 20 ) for supplying an exhaust gas aftertreament system ( 10 ) of an internal combustion engine with a reductant ( 14 ), in particular with a urea-water solution, in order to reduce nitrogen oxides (NOx) in the exhaust gas flow of the internal combustion engine, comprising a motor ( 32 ) for driving two pumps ( 22, 24 ). According to the invention, the first pump ( 22 ) is connected to the motor ( 32 ) by means of a first coupling, and the second pump ( 24 ) is connected to the motor by means of a second coupling. In a preferred embodiment, the couplings are designed as freewheel couplings ( 26, 28 ) acting in opposite directions, so that a switch between a “pumping state” and a “suck-back state” can be made by simply reversing the direction of rotation of the motor ( 32 ). | 5 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to a human protein sequence which can be used in several applications. Specifically, the novel human protein sequence can be used to design proteins which produce lower allergenic response in humans exposed to such proteins through the use of a predictive assay.
B. State of the Art
Serine proteases are a subgroup of carbonyl hydrolases. They comprise a diverse class of enzymes having a wide range of specificities and biological functions. Stroud, R. Sci. Amer., 131:74-88. Despite their functional diversity, the catalytic machinery of serine proteases has been approached by at least two genetically distinct families of enzymes: the subtilisins and the mammalian chymotrypsin related and homologous bacterial serine proteases (e.g., trypsin and S. gresius trypsin). These two families of serine proteases show remarkably similar mechanisms of catalysis. Kraut, J. (1977), Ann. Rev. Biochem., 46:331-358. Furthermore, although the primary structure is unrelated, the tertiary structure of these two enzyme families bring together a conserved catalytic triad of amino acids consisting of serine, histidine and aspartate.
Subtilisin is a serine endoprotease (MW 27,500) which is secreted in large amounts from a wide variety of Bacillus species and other microorganisms. The protein sequence of subtilisin has been determined from at least four different species of Bacillus. Markland, F. S., et al. (1983), Honne - Seyler's Z. Physiol. Chem., 364:1537-1540. The three-dimensional crystallographic structure of Bacillus amyloliquefaciens subtilisin to 2.5A resolution has also been reported. Wright, C. S., et al. (1969), Nature, 221:235-242; Drenth, J., et al. (1972), Eur. J. Biochem., 26:177-181. These studies indicate that although subtilisin is genetically unrelated to the mammalian chymotrypsin like serine proteases, it has a similar active site structure. The x-ray crystal structures of subtilisin containing covalently bound peptide inhibitors (Robertus, J. D., et al. (1972), Biochemistry, 11:2439-2449) or product complexes (Robertus, J. D., et al. (1976), J. Biol. Chem., 251:1097-1103) have also provided information regarding the active site and putative substrate binding cleft of subtilisin. In addition, a large number of kinetic and chemical modification studies have been reported for subtilisin (Philipp, M., et al. (1983), Mol. Cell. Biochem., 51:5-32; Svendsen, B. (1976), Carlsberg Res. Comm., 41:237-291; Markland, F. S. Id. ) as well as at least one report wherein the side chain of methionine at residue 222 of subtilisin was converted by hydrogen peroxide to methionine-sulfoxide (Stauffer, D. C., et al. (1965), J. Biol. Chem., 244:5333-5338) and the side chain of serine at residue 221 converted to cysteine by chemical modification (Polgar, et al. (1981), Biochimica et Biophysica Acta, 667:351-354.)
Proteins bearing some resemblance and/or homology to bacterial subtilisin have also been detected in humans as well (see e.g., Keifer et al., DNA and Cell Biol., Vol. 10, No. 10, pp. 757-769 (1991); Smeekens et al., J. Biol. Chem., Vol. 265, No. 6, pp. 2997-3000 (1990); Tomkinson et al., Biochem., Vol. 30, pp. 168-174 (1991)).
U.S. Pat. No. 4,760,025 (RE 34,606) discloses the modification of subtilisin amino acid residues corresponding to positions in Bacillus amyloliquefaciens subtilisin tyrosine −1, aspartate +32, asparagine +155, tyrosine +104, methionine +222, glycine +166, histidine +64, glycine +169, phenylalanine +189, serine +33, serine +221, tyrosine +217, glutamate +156 and alanine +152. U.S. Pat. No. 5,182,204 discloses the modification of the amino acid +224 residue in Bacillus amyloliquefaciens subtilisin and equivalent positions in other subtilisins which may be modified by way of substitution, insertion or deletion and which may be combined with modifications to the residues identified in U.S. Pat. No. 4,760,025 (RE 34,606) to form useful subtilisin mutants or variants. U.S. Pat. No. 5,155,033 discloses similar mutant subtilisins having a modification at an equivalent position to +225 of B. amyloliquefaciens subtilisin. U.S. Pat. Nos. 5,185,258 and 5,204,015 disclose mutant subtilisins having a modification at positions +123 and/or +274. U.S. Pat. No. 5,182,204 discloses the modification of many amino acid residues within subtilisin, including specifically +99, +101, +103, +107, +126, +128, +135, +197 and +204. U.S. Pat. No. 4,914,031 discloses certain subtilisin analogs, including a subtilisin modified at position +76.
Proteins, including proteases, used in industrial, pharmaceutical and commercial applications are of increasing prevalence. As a result, the increased exposure due to this prevalence has been responsible for some safety hazards caused by the sensitization of certain persons to those peptides, whereupon subsequent exposure causes extreme allergic reactions which can be injurious and even fatal. For example, proteases are known to cause dangerous hypersensitivity in some individuals. As a result, despite the usefulness of proteases in industry, e.g., in laundry detergents, cosmetics, textile treatment etc . . . , and the extensive research performed in the field to provide improved proteases which have, for example, more effective stain removal under detergency conditions, the use of proteases in industry has been problematic due to their ability to produce a hypersensitive allergenic response in some humans.
Much work has been done to alleviate these problems. Among the strategies explored to reduce immunogenic potential of protease use have been improved production processes which reduce potential contact by controlling and minimizing workplace concentrations of dust particles or aerosol carrying airborne protease, improved granulation processes which reduce the amount of dust or aerosol actually produced from the protease product, and improved recovery processes to reduce the level of potentially allergenic contaminants in the final product. However, efforts to reduce the allergenicity of protease, per se, have been relatively unsuccessful. Alternatively, efforts have been made to mask epitopes in protease which are recognized by immunoglobulin E (IgE) in hypersensitive individuals (PCT Publication No. WO 92/10755) or to enlarge or change the nature of the antigenic determinants by attaching polymers or peptides/proteins to the problematic protease.
When an adaptive immune response occurs in an exaggerated or inappropriate form, the individual experiencing the reaction is said to be hypersensitive. Hypersensitivity reactions are the result of normally beneficial immune responses acting inappropriately and sometimes cause inflammatory reactions and tissue damage. They can be provoked by many antigens; and the cause of a hypersensitivity reaction will vary from one individual to the next. Hypersensitivity does not normally manifest itself upon first contact with the antigen, but usually appears upon subsequent contact. One form of hypersensitivity occurs when an IgE response is directed against innocuous environmental antigens, such as pollen, dust-mites or animal dander. The resulting release of pharmacological mediators by IgE-sensitized mast cells produces an acute inflammatory reaction with symptoms such as asthma or rhinitis.
Nonetheless, a strategy comprising modifying the IgE sites will not generally be successful in preventing the cause of the initial sensitization reaction. Accordingly, such strategies, while perhaps neutralizing or reducing the severity of the subsequent hypersensitivity reaction, will not reduce the number or persons actually sensitized. For example, when a person is known to be hypersensitive to a certain antigen, the general, and only safe, manner of dealing with such a situation is to isolate the hypersensitive person from the antigen as completely as possible. Indeed, any other course of action would be dangerous to the health of the hypersensitive individual. Thus, while reducing the danger of a specific protein for a hypersensitive individual is important, for industrial purposes it would be far more valuable to render a protein incapable of initiating the hypersensitivity reaction in the first place.
T-lymphocytes (T-cells) are key players in the induction and regulation of immune responses and in the execution of immunological effector functions. Specific immunity against infectious agents and tumors is known to be dependent on these cells and they are believed to contribute to the healing of injuries. On the other hand, failure to control these responses can lead to auto aggression. In general, antigen is presented to T-cells in the form of antigen presenting cells which, through a variety of cell surface mechanisms, capture and display antigen or partial antigen in a manner suitable for antigen recognition by the T-cell. Upon recognition of a specific epitope by the receptors on the surface of the T-cells (T-cell receptors), the T-cells begin a series of complex interactions, including proliferation, which result in the production of antibody by B-cells. While T-cells and B-cells are both activated by antigenic epitopes which exist on a given protein or peptide, the actual epitopes recognized by these mononuclear cells are generally not identical. In fact, the epitope which activates a T-cell to initiate the creation of immunologic diversity is quite often not the same epitope which is later recognized by B-cells in the course of the immunologic response. Thus, with respect to hypersensitivity, while the specific antigenic interaction between the T-cell and the antigen is a critical element in the initiation of the immune response to antigenic exposure, the specifics of that interaction, i.e., the epitope recognized, is often not relevant to subsequent development of a full blown allergic reaction.
PCT Publication No. WO 96/40791 discloses a process for producing polyalkylene oxide-polypeptide conjugates with reduced allergenicity using polyalkylene oxide as a starting material.
PCT Publication No. WO 97/30148 discloses a polypeptide conjugate with reduced allergenicity which comprises one polymeric carrier molecule having two or more polypeptide molecules coupled covalently thereto.
PCT Publication No. WO 96/17929 discloses a process for producing polypeptides with reduced allergenicity comprising the step of conjugating from 1 to 30 polymolecules to a parent polypeptide.
PCT Publication No. WO 92/10755 discloses a method of producing protein variants evoking a reduced immunogenic response in animals. In this application, the proteins of interest, a series of proteases and variants thereof, were used to immunized rats. The sera from the rats was then used to measure the reactivity of the polyclonal antibodies already produced and present in the immunized sera to the protein of interest and variants thereof. From these results, it was possible to determine whether the antibodies in the preparation were comparatively more or less reactive with the protein and its variants, thus permitting an analysis of which changes in the protein are likely to neutralize or reduce the ability of the Ig to bind. From these tests on rats, the conclusion was arrived at that changing any of subtilisin 309 residues corresponding to 127, 128, 129, 130, 131, 151, 136, 151, 152, 153, 154, 161, 162, 163, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 186, 193, 194, 195, 196, 197, 247, 251, 261 will result in a change in the immunological potential.
PCT Publication No. WO 94/10191 discloses low allergenic proteins comprising oligomeric forms of the parent monomeric protein, wherein the oligomer has substantially retained its activity.
The prior art has provided methods of reducing the allergenicity of certain proteins and identification of epitopes which cause allergic reactions in some individuals, the assays used to identify these epitopes generally involving measurement of IgE and IgG antibody in blood sera previously exposed to the antigen. Nonetheless, a need continues for alternate methods of preparing low allergenicity enzymes. Likewise, a need exists for an increased availability of human enzymes which may have use in pharmaceutical applications.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a human protease which can be used in industry as a replacement for bacterial and fungal proteases.
It is an object of the invention to provide a method of making currently used and successful proteases and other proteins more safe by integrating therein sequences derived from human protease analogs.
It is a further object of the invention to provide a human protease which may have application in the pharmaceutical industry.
According to the present invention, a method for reducing the allergenicity of a non-human protein is provided wherein an epitope is identified and replaced with an analogous region within a human subtilisin. In a preferred embodiment the non-human protein is an enzyme, more preferably a protease. In another preferred embodiment, the epitope replaced is a T-cell epitope.
In another embodiment of the present invention, a method for producing the protein of the invention having reduced allergenicity is provided. Preferably, the mutant protein is prepared by modifying a DNA encoding a precursor protein so that the modified DNA encodes the mutant protein of the invention wherein an epitope is replaced with an analogous region from human subtilisin.
In yet another embodiment of the invention, DNA sequences encoding the mutant protein, as well as expression vectors containing such DNA sequences and host cells transformed with such vectors are provided, which host cells are preferably capable of expressing such DNA to produce the mutant protein of the invention either intracellularly or extracellularly.
The mutant protein of the invention is useful in any composition or process in which the protein is generally known to be useful. For example, where the protein is a protease, the reduced allergenicity protease can be used as a component in cleaning products such as laundry detergents and hard surface cleansers, as an aid in the preparation of leather, in the treatment of textiles such as wool and/or silk to reduce felting, as a component in a cosmetic or face cream, and as a component in animal or pet feed to improve the nutritional value of the feed. Similarly, where the protein is an amylase, the reduced allergenicity amylase can be used for the liquefaction of starch, as a component in a dishwashing detergent, for desizing of textiles, in a laundry detergent or any other use for which amylase is useful. Similarly, where the protein is a pharmaceutical composition, its use can be made more safe by reducing the possibility of allergic reaction.
In another embodiment of the invention, the human subtilisin may be used in pharmaceutical applications wherein the protease is used for debridement treatments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-C illustrates the DNA (SEQ ID:NO 1) and amino acid (SEQ ID:NO 2) sequence for Bacillus amyloliquefaciens subtilisin (BPN′) and a partial restriction map of this gene.
FIG. 2 illustrates the conserved amino acid residues among subtilisins from Bacillus amyloliquefaciens (SEQ ID NO: 2), and Bacillus lentus (wild-type)(SEQ ID:NO 3).
FIGS. 3A and 3B illustrate an amino acid sequence alignment of subtilisin type proteases from Bacillus amyloliquefaciens (BPN′) (SEQ ID NO: 2), Bacillus subtilis (SEQ ID NO: 5), Bacillus licheniformis (SEQ ID:NO 4) and Bacillus lentus (SEQ ID NO: 3). The symbol * denotes the absence of specific amino acid residues as compared to subtilisin BPN′.
FIG. 4 . illustrates the additive T-cell response of 16 peripheral mononuclear blood samples to peptides corresponding to the Bacillus lentus protease. Peptide E05 represents the region comprising residues corresponding to 170-173 in protease from Bacillus amyloliquefaciens.
FIG. 5 illustrate the additive T-cell response of 10 peripheral mononuclear blood sample to peptides corresponding to the human subtilisin.
FIG. 6 illustrates the amino acid sequence of human subtilisin (SEQ ID:NO 6).
FIGS. 7A, 7 B and 7 C illustrates the amino acid strings corresponding to peptides derived from the sequence of Bacillus lentus protease used in Example 2.
FIGS. 8A, 8 B, and 8 C illustrate the amino acid strings corresponding to peptides derived from the sequence of human subtilisin used in Example 2.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, a method for reducing the allergenicity of a non-human protein is provided wherein an epitope is identified and replaced with an analogous region within a human subtilisin. In a preferred embodiment the non-human protein is an enzyme, more preferably a protease. In another preferred embodiment, the epitope replaced is a T-cell epitope.
In another embodiment of the present invention, a method for producing the protein of the invention having reduced allergenicity is provided. Preferably, the mutant protein is prepared by modifying a DNA encoding a precursor protein so that the modified DNA encodes the mutant protein of the invention wherein an epitope is replaced with an analogous region from human subtilisin.
In yet another embodiment of the invention, DNA sequences encoding the mutant protein, as well as expression vectors containing such DNA sequences and host cells transformed with such vectors are provided, which host cells are preferably capable of expressing such DNA to produce the mutant protein of the invention either intracellularly or extracellularly.
According to a preferred embodiment of the present invention, the epitope to be replaced in the non-human protein of interest is identified by a method for identifying T-cell epitopes. In a preferred embodiment of the invention, the present invention provides an assay which identifies epitopes as follows: differentiated dendritic cells are combined with naive human CD4+ and/or CD8+ T-cells and with a peptide of interest. More specifically, a method is provided wherein a T-cell epitope is recognized comprising the steps of: (a) obtaining from a single blood source a solution of dendritic cells and a solution of naive CD4+ and/or CD8+ T-cells; (b) promoting differentiation in said solution of dendritic cells; (c) combining said solution of differentiated dendritic cells and said naive CD4+ and/or CD8+ T-cells with a peptide of interest; (d) measuring the proliferation of T-cells in said step (c).
The non-human peptide of interest to be analyzed according to the assay of the invention is derived from a protein or enzyme for which reduced allergenicity is required. In the practice of the invention, it is possible to identify with precision the location of an epitope which can cause sensitization in an individual or sampling of individuals. In a particularly effective embodiment of the invention, a series of peptide oligomers which correspond to all or part of the protein or enzyme are prepared. For example, a peptide library is produced covering the relevant portion or all of the protein. One particularly useful manner of producing the peptides is to introduce overlap into the peptide library, for example, producing a first peptide corresponds to amino acid sequence 1-10 of the subject protein, a second peptide corresponds to amino acid sequence 4-14 of the subject protein, a third peptide corresponds to amino acid sequence 7-17 of the subject protein, a fourth peptide corresponds to amino acid sequence 10-20 of the subject protein etc . . . until representative peptides corresponding to the entire molecule are created. By analyzing each of the peptides individually in the assay provided herein, it is possible to precisely identify the location of epitopes recognized by T-cells. In the example above, the reaction of one specific peptide to a greater extent than it's neighbors will facilitate identification of the epitope anchor region to within three amino acids. After determining the location of these epitopes, it is possible to alter the amino acids within each epitope until the peptide produces a less significant T-cell response.
Preferably, the epitope is modified in one of the following ways: (a) preferably the amino acid sequence of the epitope is substituted with an analogous sequence from the human subtilisin of the invention to the protein of interest, e.g., where the protein is a subtilisin, a sequence alignment can be arranged so as to find the analogous region in the human subtilisin molecule with which to replace the pertinent epitope in the subtilisin; (b) the amino acid sequence of the epitope is substituted with a sequence from human subtilisin of the invention which substantially mimics the major tertiary structure attributes of the epitope, but which produces a lesser allergenic response due to T-cell epitope recognition than that of the protein of interest; or (c) with any sequence from the human subtilisin of the invention which produces lesser allergenic response due to T-cell epitope recognition than that of the protein of interest.
“Antigen presenting cell” as used herein means a cell of the immune system which present antigen on their surface which is recognizable by T-cells. Examples of antigen presenting cells are dendritic cells, interdigitating cells, activated B-cells and macrophages.
“T-cell proliferation” as used herein means the number of T-cells produced during the incubation of T-cells with the antigen presenting cells, with or without antigen.
“Baseline T-cell proliferation” as used herein means T-cell proliferation which is normally seen in an individual in response to exposure to antigen presenting cells in the absence of peptide or protein antigen. For the purposes herein, the baseline T-cell proliferation level was determined on a per sample basis for each individual as the proliferation of T-cells in response to antigen presenting cells in the absence of antigen.
“T-cell epitope” means a feature of a peptide or protein which is recognized by a T-cell receptor in the initiation of an immunologic response to the peptide comprising that antigen. Recognition of a T-cell epitope by a T-cell is generally believed to be via a mechanism wherein T-cells recognize peptide fragments of antigens which are bound to class I or class II major histocompatability (MHC) molecules expressed on antigen-presenting cells (see e.g., Moeller, G. ed., Antigenic Requirements for Activation of MHC-Restricted Responses, Immunological Review, Volume 98, p 187 (Copenhagen; Munksgaard) (1987).
The epitopes determined according to the assay provided herein are then modified to reduce the allergenic potential of the protein of interest. In a preferred embodiment, the epitope to be modified produces a level of T-cell proliferation of greater than three times the baseline T-cell proliferation in a sample. When modified, the epitope produces less than three times the baseline proliferation, preferably less than two times the baseline proliferation and most preferably less than or substantially equal to the baseline proliferation in a sample.
“Sample” as used herein comprises mononuclear cells which are naive, i.e., not sensitized, to the antigen in question.
“Homolog” as used herein means a protein or enzyme which has similar catalytic action, structure and/or use as the protein of interest. It is desirable to find a homolog that has a tertiary and/or primary structure similar to the protein of interest as replacement of the epitope in the protein of interest with an analogous segment from the homolog will reduce the disruptiveness of the change. Thus, enzymes having significant homology will provide the most desirable target for epitope substitutions with sequences from the human subtilisin of the invention.
An “analogous” sequence may be determined by ensuring that the replacement amino acids show a similar function, the tertiary structure and/or conserved residues to the amino acids in the protein of interest at or near the epitope. Thus, where the epitope region contains, for example, an alpha-helix or a beta-sheet structure, the replacement amino acids should maintain that specific structure.
While the present invention extends to all proteins for which it is desired to reduce allergenicity, for the sake of simplicity, the following will describe a particularly preferred embodiment of the invention, the modification of protease. Proteases are carbonyl hydrolases which generally act to cleave peptide bonds of proteins or peptides. As used herein, “protease” means a naturally-occurring protease or a recombinant protease. Naturally-occurring proteases include α-aminoacylpeptide hydrolase, peptidylamino acid hydrolase, acylamino hydrolase, serine carboxypeptidase, metallocarboxypeptidase, thiol proteinase, carboxylproteinase and metalloproteinase. Serine, metallo, thiol and acid proteases are included, as well as endo and exo-proteases.
Subtilisins are bacterial or fungal proteases which generally act to cleave peptide bonds of proteins or peptides. As used herein, “subtilisin” means a naturally-occurring subtilisin or a recombinant subtilisin. A series of naturally-occurring subtilisins is known to be produced and often secreted by various microbial species. Amino acid sequences of the members of this series are not entirely homologous. However, the subtilisins in this series exhibit the same or similar type of proteolytic activity. This class of serine proteases shares a common amino acid sequence defining a catalytic triad which distinguishes them from the chymotrypsin related class of serine proteases. The subtilisins and chymotrypsin related serine proteases both have a catalytic triad comprising aspartate, histidine and serine. In the subtilisin related proteases the relative order of these amino acids, reading from the amino to carboxy terminus, is aspartate-histidine-serine. In the chymotrypsin related proteases, the relative order, however, is histidine-aspartate-serine. Thus, subtilisin herein refers to a serine protease having the catalytic triad of subtilisin related proteases. Examples include but are not limited to the subtilisins identified in FIG. 3 herein. Generally and for purposes of the present invention, numbering of the amino acids in proteases corresponds to the numbers assigned to the mature Bacillus amyloliquefaciens subtilisin sequence presented in FIG. 1 .
“Recombinant subtilisin” or “recombinant protease” refer to a subtilisin or protease in which the DNA sequence encoding the subtilisin or protease is modified to produce a variant (or mutant) DNA sequence which encodes the substitution, deletion or insertion of one or more amino acids in the naturally-occurring amino acid sequence. Suitable methods to produce such modification, and which may be combined with those disclosed herein, include those disclosed in U.S. Pat. Nos. 4,760,025 (RE 34,606), 5,204,015 and 5,185,258.
“Non-human subtilisins” and the DNA encoding them may be obtained from many procaryotic and eucaryotic organisms. Suitable examples of procaryotic organisms include gram negative organisms such as E. coli or Pseudomonas and gram positive bacteria such as Micrococcus or Bacillus. Examples of eucaryotic organisms from which subtilisin and their genes may be obtained include yeast such as Saccharomyces cerevisiae , fungi such as Aspergillus sp.
“Human subtilisin” means the protein represented by the sequence in FIG. 6, derivatives thereof or modifications thereof which retain the essential ability to hydrolyze peptide bonds.
A “protease variant” has an amino acid sequence which is derived from the amino acid sequence of a “precursor protease”. The precursor proteases include naturally-occurring proteases and recombinant proteases. The amino acid sequence of the protease variant is “derived” from the precursor protease amino acid sequence by the substitution, deletion or insertion of one or more amino acids of the precursor amino acid sequence. Such modification is of the “precursor DNA sequence” which encodes the amino acid sequence of the precursor protease rather than manipulation of the precursor protease enzyme per se. Suitable methods for such manipulation of the precursor DNA sequence include methods disclosed herein, as well as methods known to those skilled in the art (see, for example, EP 0 328299, WO89/06279 and the US patents and applications already referenced herein).
These amino acid position numbers used herein refer to those assigned to the mature Bacillus amyloliquefaciens subtilisin sequence presented in FIG. 1 . The invention, however, is not limited to the mutation of this particular subtilisin but extends to precursor proteases containing amino acid residues at positions which are “equivalent” to the particular identified residues in Bacillus amyloliquefaciens subtilisin. In a preferred embodiment of the present invention, the precursor protease is Bacillus lentus subtilisin and the substitutions, deletions or insertions are made at the equivalent amino acid residue in B. lentus corresponding to those listed above.
A residue (amino acid) of a precursor protease is equivalent to a residue of Bacillus amyloliquefaciens subtilisin if it is either homologous (i.e., corresponding in position in either primary or tertiary structure) or analogous to a specific residue or portion of that residue in Bacillus amyloliquefaciens subtilisin (i.e., having the same or similar functional capacity to combine, react, or interact chemically).
In order to establish homology to primary structure, the amino acid sequence of a precursor protease is directly compared to the Bacillus amyloliquefaciens subtilisin primary sequence and particularly to a set of residues known to be invariant in subtilisins for which sequence is known. For example, FIG. 2 herein shows the conserved residues as between B. amyloliquefaciens subtilisin and B. lentus subtilisin. After aligning the conserved residues, allowing for necessary insertions and deletions in order to maintain alignment (i.e., avoiding the elimination of conserved residues through arbitrary deletion and insertion), the residues equivalent to particular amino acids in the primary sequence of Bacillus amyloliquefaciens subtilisin are defined. Alignment of conserved residues preferably should conserve 100% of such residues. However, alignment of greater than 75% or as little as 50% of conserved residues is also adequate to define equivalent residues. Conservation of the catalytic triad, Asp32/His64/Ser221 should be maintained.
For example, in FIG. 6 the amino acid sequence of subtilisin from Bacillus amyloliquefaciens, Bacillus subtilis, Bacillus licheniformis (carlsbergensis) and Bacillus lentus are aligned to provide the maximum amount of homology between amino acid sequences. A comparison of these sequences shows that there are a number of conserved residues contained in each sequence. These conserved residues (as between BPN′ and B. lentus ) are identified in FIG. 2 .
These conserved residues, thus, may be used to define the corresponding equivalent amino acid residues of Bacillus amyloliquefaciens subtilisin in other subtilisins such as subtilisin from Bacillus lentus (PCT Publication No. WO89/06279 published Jul. 13, 1989), the preferred protease precursor enzyme herein, or the subtilisin referred to as PB92 (EP 0 328 299), which is highly homologous to the preferred Bacillus lentus subtilisin. The amino acid sequences of certain of these subtilisins are aligned in FIGS. 3A and 3B with the sequence of Bacillus amyloliquefaciens subtilisin to produce the maximum homology of conserved residues. As can be seen, there are a number of deletions in the sequence of Bacillus lentus as compared to Bacillus amyloliquefaciens subtilisin. Thus, for example, the equivalent amino acid for Vail 65 in Bacillus amyloliquefaciens subtilisin in the other subtilisins is isoleucine for B. lentus and B. licheniformis.
Thus, for example, the amino acid at position +170 is lysine (K) in both B. amyloliquefaciens and B. licheniformis subtilisins and arginine (R) in Savinase. In the protease variants of the invention, however, the amino acid equivalent to +170 in Bacillus amyloliquefaciens subtilisin is substituted with aspartic acid (D). The abbreviations and one letter codes for all amino acids in the present invention conform to the PatentIn User Manual (GenBank, Mountain View, Calif.) 1990, p. 101.
“Equivalent residues” may also be defined by determining homology at the level of tertiary structure for a precursor protease whose tertiary structure has been determined by x-ray crystallography. Equivalent residues are defined as those for which the atomic coordinates of two or more of the main chain atoms of a particular amino acid residue of the precursor protease and Bacillus amyloliquefaciens subtilisin (N on N, CA on CA, C on C and O on O) are within 0.13 nm and preferably 0.1 nm after alignment. Alignment is achieved after the best model has been oriented and positioned to give the maximum overlap of atomic coordinates of non-hydrogen protein atoms of the protease in question to the Bacillus amyloliquefaciens subtilisin. The best model is the crystallographic model giving the lowest R factor for experimental diffraction data at the highest resolution available. Rfactor = ∑ h Fo ( h ) - Fc ( h ) ∑ h Fo ( h )
Equivalent residues which are functionally analogous to a specific residue of Bacillus amyloliquefaciens subtilisin are defined as those amino acids of the precursor protease which may adopt a conformation such that they either alter, modify or contribute to protein structure, substrate binding or catalysis in a manner defined and attributed to a specific residue of the Bacillus amyloliquefaciens subtilisin. Further, they are those residues of the precursor protease (for which a tertiary structure has been obtained by x-ray crystallography) which occupy an analogous position to the extent that, although the main chain atoms of the given residue may not satisfy the criteria of equivalence on the basis of occupying a homologous position, the atomic coordinates of at least two of the side chain atoms of the residue lie with 0.13 nm of the corresponding side chain atoms of Bacillus amyloliquefaciens subtilisin. The coordinates of the three dimensional structure of Bacillus amyloliquefaciens subtilisin are set forth in EPO Publication No. 0 251 446 (equivalent to U.S. Pat. No. 5,182,204, the disclosure of which is incorporated herein by reference) and can be used as outlined above to determine equivalent residues on the level of tertiary structure.
Some of the residues identified for substitution, insertion or deletion are conserved residues whereas others are not. In the case of residues which are not conserved, the replacement of one or more amino acids is limited to substitutions which produce a variant which has an amino acid sequence that does not correspond to one found in nature. In the case of conserved residues, such replacements should not result in a naturally-occurring sequence. The protease variants of the present invention include the mature forms of protease variants, as well as the pro- and prepro-forms of such protease variants. The prepro-forms are the preferred construction since this facilitates the expression, secretion and maturation of the protease variants.
“Prosequence” refers to a sequence of amino acids bound to the N-terminal portion of the mature form of a protease which when removed results in the appearance of the “mature” form of the protease. Many proteolytic enzymes are found in nature as translational proenzyme products and, in the absence of post-translational processing, are expressed in this fashion. A preferred prosequence for producing protease variants is the putative prosequence of Bacillus amyloliquefaciens subtilisin, although other protease prosequences may be used.
A “signal sequence” or “presequence” refers to any sequence of amino acids bound to the N-terminal portion of a protease or to the N-terminal portion of a proprotease which may participate in the secretion of the mature or pro forms of the protease. This definition of signal sequence is a functional one, meant to include all those amino acid sequences encoded by the N-terminal portion of the protease gene which participate in the effectuation of the secretion of protease under native conditions. The present invention utilizes such sequences to effect the secretion of the protease variants as defined herein. One possible signal sequence comprises the first seven amino acid residues of the signal sequence from Bacillus subtilis subtilisin fused to the remainder of the signal sequence of the subtilisin from Bacillus lentus (ATCC 21536).
A “prepro” form of a protease variant consists of the mature form of the protease having a prosequence operably linked to the amino terminus of the protease and a “pre” or “signal” sequence operably linked to the amino terminus of the prosequence.
“Expression vector” refers to a DNA construct containing a DNA sequence which is operably linked to a suitable control sequence capable of effecting the expression of said DNA in a suitable host. Such control sequences include a promoter to effect transcription, an optional operator sequence to control such transcription, a sequence encoding suitable mRNA ribosome binding sites and sequences which control termination of transcription and translation. The vector may be a plasmid, a phage particle, or simply a potential genomic insert. Once transformed into a suitable host, the vector may replicate and function independently of the host genome, or may, in some instances, integrate into the genome itself. In the present specification, “plasmid” and “vector” are sometimes used interchangeably as the plasmid is the most commonly used form of vector at present. However, the invention is intended to include such other forms of expression vectors which serve equivalent functions and which are, or become, known in the art.
The “host cells” used in the present invention generally are procaryotic or eucaryotic hosts which preferably have been manipulated by the methods disclosed in U.S. Pat. No. 4,760,025 (RE 34,606) to render them incapable of secreting enzymatically active endoprotease. A preferred host cell for expressing protease is the Bacillus strain BG2036 which is deficient in enzymatically active neutral protease and alkaline protease (subtilisin). The construction of strain BG2036 is described in detail in U.S. Pat. No. 5,264,366. Other host cells for expressing protease include Bacillus subtilis 1168 (also described in U.S. Pat. No. 4,760,025 (RE 34,606) and U.S. Pat. No. 5,264,366, the disclosure of which are incorporated herein by reference), as well as any suitable Bacillus strain such as B. licheniformis, B. lentus, etc.
Host cells are transformed or transfected with vectors constructed using recombinant DNA techniques. Such transformed host cells are capable of either replicating vectors encoding the protease variants or expressing the desired protease variant. In the case of vectors which encode the pre- or prepro-form of the protease variant, such variants, when expressed, are typically secreted from the host cell into the host cell medium.
“Operably linked, ” when describing the relationship between two DNA regions, simply means that they are functionally related to each other. For example, a presequence is operably linked to a peptide if it functions as a signal sequence, participating in the secretion of the mature form of the protein most probably involving cleavage of the signal sequence. A promoter is operably linked to a coding sequence if it controls the transcription of the sequence; a ribosome binding site is operably linked to a coding sequence if it is positioned so as to permit translation.
The genes encoding the naturally-occurring precursor protease may be obtained in accord with the general methods known to those skilled in the art. The methods generally comprise synthesizing labeled probes having putative sequences encoding regions of the protease of interest, preparing genomic libraries from organisms expressing the protease, and screening the libraries for the gene of interest by hybridization to the probes. Positively hybridizing clones are then mapped and sequenced.
The cloned protease is then used to transform a host cell in order to express the protease. The protease gene is then ligated into a high copy number plasmid. This plasmid replicates in hosts in the sense that it contains the well-known elements necessary for plasmid replication: a promoter operably linked to the gene in question (which may be supplied as the gene's own homologous promoter if it is recognized, i.e., transcribed, by the host), a transcription termination and polyadenylation region (necessary for stability of the mRNA transcribed by the host from the protease gene in certain eucaryotic host cells) which is exogenous or is supplied by the endogenous terminator region of the protease gene and, desirably, a selection gene such as an antibiotic resistance gene that enables continuous cultural maintenance of plasmid-infected host cells by growth in antibiotic-containing media. High copy number plasmids also contain an origin of replication for the host, thereby enabling large numbers of plasmids to be generated in the cytoplasm without chromosomal limitations. However, it is within the scope herein to integrate multiple copies of the protease gene into host genome. This is facilitated by procaryotic and eucaryotic organisms which are particularly susceptible to homologous recombination.
In one embodiment, the gene can be a natural gene such as that from B lentus or B. amyloliquefaciens . Alternatively, a synthetic gene encoding a naturally-occurring or mutant precursor protease may be produced. In such an approach, the DNA and/or amino acid sequence of the precursor protease is determined. Multiple, overlapping synthetic single-stranded DNA fragments are thereafter synthesized, which upon hybridization and ligation produce a synthetic DNA encoding the precursor protease. An example of synthetic gene construction is set forth in Example 3 of U.S. Pat. No. 5,204,015, the disclosure of which is incorporated herein by reference.
Once the naturally-occurring or synthetic precursor protease gene has been cloned, a number of modifications are undertaken to enhance the use of the gene beyond synthesis of the naturally-occurring precursor protease. Such modifications include the production of recombinant proteases as disclosed in U.S. Pat. No. 4,760,025 (RE 34,606) and EPO Publication No. 0 251 446 and the production of protease variants described herein.
The following cassette mutagenesis method may be used to facilitate the construction of the protease variants of the present invention, although other methods may be used. First, the naturally-occurring gene encoding the protease is obtained and sequenced in whole or in part. Then the sequence is scanned for a point at which it is desired to make a mutation (deletion, insertion or substitution) of one or more amino acids in the encoded enzyme. The sequences flanking this point are evaluated for the presence of restriction sites for replacing a short segment of the gene with an oligonucleotide pool which when expressed will encode various mutants. Such restriction sites are preferably unique sites within the protease gene so as to facilitate the replacement of the gene segment. However, any convenient restriction site which is not overly redundant in the protease gene may be used, provided the gene fragments generated by restriction digestion can be reassembled in proper sequence. If restriction sites are not present at locations within a convenient distance from the selected point (from 10 to 15 nucleotides), such sites are generated by substituting nucleotides in the gene in such a fashion that neither the reading frame nor the amino acids encoded are changed in the final construction. Mutation of the gene in order to change its sequence to conform to the desired sequence is accomplished by M13 primer extension in accord with generally known methods. The task of locating suitable flanking regions and evaluating the needed changes to arrive at two convenient restriction site sequences is made routine by the redundancy of the genetic code, a restriction enzyme map of the gene and the large number of different restriction enzymes. Note that if a convenient flanking restriction site is available, the above method need be used only in connection with the flanking region which does not contain a site.
Once the naturally-occurring DNA or synthetic DNA is cloned, the restriction sites flanking the positions to be mutated are digested with the cognate restriction enzymes and a plurality of end termini-complementary oligonucleotide cassettes are ligated into the gene. The mutagenesis is simplified by this method because all of the oligonucleotides can be synthesized so as to have the same restriction sites, and no synthetic linkers are necessary to create the restriction sites.
In one aspect of the invention, the objective is to secure a variant protease having altered allergenic potential as compared to the precursor protease, since decreasing such potential enables safer use of the enzyme. While the instant invention is useful to lower allergenic potential, the mutations specified herein may be utilized in combination with mutations known in the art to result altered thermal stability and/or altered substrate specificity, modified activity or altered alkaline stability as compared to the precursor.
Thus, in combination with the mutations of the present invention, substitutions at positions corresponding to N76D/S103A/V104I/G159D optionally in combination with one or more substitutions selected from the group consisting of positions corresponding to V68A, T213R, A232V, Q236H, Q245R, and T260A of Bacillus amyloliquefaciens subtilisin may be used, in addition to decreasing the allergenic potential of the variant protease of the invention, to modulate overall stability and/or proteolytic activity of the enzyme. Similarly, the substitutions provided herein may be combined with mutation at the Asparagine (N) in Bacillus lentus subtilisin at equivalent position +76 to Aspartate (D) in combination with the mutations S103A/V104I/G159D and optionally in combination with one or more substitutions selected from the group consisting of positions corresponding to V68A, T213R, A232V, Q236H, Q245R, and T260A of Bacillus amyloliquefaciens subtilisin, to produce enhanced stability and/or enhanced activity of the resulting mutant enzyme.
Based on the screening results obtained with the variant proteases, the noted mutations in Bacillus amyloliquefaciens subtilisin are important to the proteolytic activity, performance and/or stability of these enzymes and the cleaning or wash performance of such variant enzymes.
Many of the protease variants of the invention are useful in formulating various detergent compositions. A number of known compounds are suitable surfactants useful in compositions comprising the protease mutants of the invention. These include nonionic, anionic, cationic, anionic or zwitterionic detergents, as disclosed in U.S. Pat. No. 4,404,128 to Barry J. Anderson and U.S. Pat. No. 4,261,868 to Jiri Flora, et al. A suitable detergent formulation is that described in Example 7 of U.S. Pat. No. 5,204,015 (previously incorporated by reference). The art is familiar with the different formulations which can be used as cleaning compositions. In addition to typical cleaning compositions, it is readily understood that the protease variants of the present invention may be used for any purpose that native or wild-type proteases are used. Thus, these variants can be used, for example, in personal care items such as face lotions and cosmetics, in bar or liquid soap applications, dishcare formulations, contact lens cleaning solutions or products, peptide hydrolysis, waste treatment, textile applications, as fusion-cleavage enzymes in protein production, etc. The variants of the present invention may comprise enhanced performance in a detergent composition (as compared to the precursor). As used herein, enhanced performance in a detergent is defined as increasing cleaning of certain enzyme sensitive stains such as grass or blood, as determined by usual evaluation after a standard wash cycle.
Proteases of the invention can be formulated into known powdered and liquid detergents having pH between 6.5 and 12.0 at levels of about 0.01 to about 5% (preferably 0.1% to 0.5%) by weight. These detergent cleaning compositions can also include other enzymes such as known proteases, amylases, cellulases, lipases or endoglycosidases, as well as builders and stabilizers.
The addition of proteases of the invention to conventional cleaning compositions does not create any special use limitation. In other words, any temperature and pH suitable for the detergent is also suitable for the present compositions as long as the pH is within the above range, and the temperature is below the described protease's denaturing temperature. In addition, proteases of the invention can be used in a cleaning composition without detergents, again either alone or in combination with builders and stabilizers.
The variant proteases of the present invention can be included in animal feed such as part of animal feed additives as described in, for example, U.S. Pat. No. 5,612,055; U.S. Pat. No. 5,314,692; and U.S. Pat. No. 5,147,642.
One aspect of the invention is a composition for the treatment of a textile that includes variant proteases of the present invention. The composition can be used to treat for example silk or wool as described in publications such as RD 216,034; EP 134,267; U.S. Pat. No. 4,533,359; and EP 344,259.
The following is presented by way of example and is not to be construed as a limitation to the scope of the claims. All publications and patents referenced herein are hereby incorporated by reference in their entirety.
EXAMPLES
Example 1
Assay for the Identification of Peptide T-Cell Epitopes Using Naive Human T-Cells
Fresh human peripheral blood cells were collected from “naive” humans, i.e., persons not known to be exposed to or sensitized to Bacillus lentus protease, for determination of antigenic epitopes in protease from Bacillus lentus and human subtilisin. Naive humans is intended to mean that the individual is not known to have been exposed to or developed a reaction to protease in the past. Peripheral mononuclear blood cells (stored at room temperature, no older than 24 hours) were prepared for use as follows: Approximately 30 mls of a solution of buffy coat preparation from one unit of whole blood was brought to 50 ml with Dulbecco's phosphate buffered solution (DPBS) and split into two tubes. The samples were underlaid with 12.5 ml of room temperature lymphoprep density separation media (Nycomed density 1.077 g/ml). The tubes were centrifuged for thirty minutes at 600G. The interface of the two phases was collected, pooled and washed in DPBS. The cell density of the resultant solution was measured by hemocytometer. Viability was measured by trypan blue exclusion.
From the resulting solution, a differentiated dendritic cell culture was prepared from the peripheral blood mononuclear cell sample having a density of 10 8 cells per 75 ml culture flask in a solution as follows:
(1) 50 ml of serum free AIM V media (Gibco) was supplemented with a 1:100 dilution beta-mercaptoethanol (Gibco). The flasks were laid flat for two hours at 37° C. in 5% CO 2 to allow adherence of monocytes to the flask wall.
(2) Differentiation of the monocyte cells to dendritic cells was as follows: nonadherent cells were removed and the resultant adherent cells (monocytes) combined with 30 ml of AIM V, 800 units/ml of GM-CSF (Endogen) and 500 units/ml of IL-4 (Endogen); the resulting mixture was cultured for 5 days under conditions at 37° C. in 5% CO 2 . After five days, the cytokine TNF(α) (Endogen) was added to 0.2 units/ml, and the cytokine IL-1α (Endogen) was added to a final concentration of 50 units/ml and the mixture incubated at 37° C. in 5% CO 2 for two more days.
(3) On the seventh day, Mitomycin C was added to a concentration of 50 microgram/ml was added to stop growth of the now differentiated dendritic cell culture. The solution was incubated for 60 minutes at 37° C. in 5% CO 2 . Dendritic cells were collected by gently scraping the adherent cells off the bottom of the flask with a cell scraper. Adherent and non-adherent cells were then centrifuged at 600G for 5 minutes, washed in DPBS and counted.
(4) The prepared dendritic cells were placed into a 96 well round bottom array at 2×10 4 /well in 100 microliter total volume.
CD4+ T cells were prepared from frozen aliquots of the peripheral blood cell samples used to prepare the dendritic cells using the human CD4+ Cellect Kit (Biotex) as per the manufacturers instructions with the following modifications: the aliquots were thawed and washed such that approximately 10 8 cells will be applied per Cellect column; the cells were resuspended in 4 ml DPBS and 1 ml of the Cell reagent from the Cellect Kit, the solution maintained at room temperature for 20 minutes. The resultant solution was centrifuged for five minutes at 600G at room temperature and the pellet resuspended in 2 ml of DPBS and applied to the Cellect columns. The effluent from the columns was collected in 2% human serum in DPBS. The resultant CD4+ cell solution was centrifuged, resuspended in AIMV media and the density counted.
The CD4+ T-cell suspension was resuspended to a count of 2×10 6 /ml in AIM V media to facilitate efficient manipulation of the 96 well plate.
Peptide antigen is prepared from a 1M stock solution in DMSO by dilution in AIM V media at a 1:10 ratio. 10 microliters of the stock solution is placed in each well of the 96 well plate containing the differentiated dendritic cells. 100 microliter of the diluted CD4+ T-cell solution as prepared above is further added to each well. Useful controls include diluted DMSO blanks, and tetanus toxoid positive controls.
The final concentrations in each well, at 210 microliter total volume are as follows:
2×10 5 CD4+
2×10 4 dendtritic cells (R:S of 10:1)
5 mM/10 4 peptide
Example 2
Identification of T-Cell Epitopes in Protease from Bacillus lentus and Human subtilisin
Peptides for use in the assay described in Example 1 were prepared based on the Bacillus lentus and human subtilisin amino acid sequence. Peptide antigens were designed as follows. From the full length amino acid sequence of either human subtilisin or Bacillus lentus protease provided in FIG. 1, 15mers were synthetically prepared, each 15 mer overlapping with the previous and the subsequent 15 mer except for three residues.
Peptides used correspond to amino acid residue strings in Bacillus lentus as provided in FIG. 7, and peptides correspond to amino acid residues in human subtilisin as provided in FIG. 8 . The key for the coded results is provided in FIG. 10 . All tests were performed at least in duplicate. All tests reported displayed robust positive control responses to the antigen tetanus toxoid. Responses were averaged within each experiment, then normalized to the baseline response. A positive event was recorded if the response was at least 3 times the baseline response.
The immunogenic response (i.e., T-cell proliferation) to the prepared peptides from human subtilisin and Bacillus lentus was tallied and is provided in FIGS. 4 and 5, respectively. T-cell proliferation was measured by the incorporated tritium method. The results shown in FIGS. 4 and 5 as a comparison of the immunogenic additive response in 10 individuals (FIG. 4) and 16 individuals (FIG. 5) to the various peptides. Response is indicated as the added response wherein 1.0 equals a baseline response for each sample. Thus, in FIG. 4, a reading of 10.0 or less is the baseline response and in FIG. 5 a reading of 16.0 or less the baseline response.
As indicated in FIGS. 4 and 5, the immunogenic response of the naive blood samples from unsensitized individuals showed a marked allergenic response at the peptide fragment from Bacillus lentus corresponding to residues 170-173 of Bacillus amyloliquefaciens protease. As expected, the corresponding fragment in human subtilisin evokes merely baseline response.
7
1
1497
DNA
B. amyloliquefaciens
CDS
(96)...(1245)
1
ggtctactaa aatattattc catactatac aattaataca cagaataatc tgtctattgg 60
ttattctgca aatgaaaaaa aggagaggat aaaga gtg aga ggc aaa aaa gta 113
Val Arg Gly Lys Lys Val
1 5
tgg atc agt ttg ctg ttt gct tta gcg tta atc ttt acg atg gcg ttc 161
Trp Ile Ser Leu Leu Phe Ala Leu Ala Leu Ile Phe Thr Met Ala Phe
10 15 20
ggc agc aca tcc tct gcc cag gcg gca ggg aaa tca aac ggg gaa aag 209
Gly Ser Thr Ser Ser Ala Gln Ala Ala Gly Lys Ser Asn Gly Glu Lys
25 30 35
aa tat att gtc ggg ttt aaa cag aca atg agc acg atg agc gcc gct 257
Lys Tyr Ile Val Gly Phe Lys Gln Thr Met Ser Thr Met Ser Ala Ala
40 45 50
aag aag aaa gat gtc att tct gaa aaa ggc ggg aaa gtg caa aag caa 305
Lys Lys Lys Asp Val Ile Ser Glu Lys Gly Gly Lys Val Gln Lys Gln
55 60 65 70
ttc aaa tat gta gac gca gct tca gtc aca tta aac gaa aaa gct gta 353
Phe Lys Tyr Val Asp Ala Ala Ser Val Thr Leu Asn Glu Lys Ala Val
75 80 85
aaa gaa ttg aaa aaa gac ccg agc gtc gct tac gtt gaa gaa gat cac 401
Lys Glu Leu Lys Lys Asp Pro Ser Val Ala Tyr Val Glu Glu Asp His
90 95 100
ta gca cat gcg tac gcg cag tcc gtg cct tac ggc gta tca caa att 449
Val Ala His Ala Tyr Ala Gln Ser Val Pro Tyr Gly Val Ser Gln Ile
105 110 115
aaa gcc cct gct ctg cac tct caa ggc tac act gga tca aat gtt aaa 497
Lys Ala Pro Ala Leu His Ser Gln Gly Tyr Thr Gly Ser Asn Val Lys
120 125 130
gta gcg gtt atc gac agc ggt atc gat tct tct cat cct gat tta aag 545
Val Ala Val Ile Asp Ser Gly Ile Asp Ser Ser His Pro Asp Leu Lys
135 140 145 150
gta gca agc gga gcc agc atg gtt cct tct gaa aca aat cct ttc caa 593
Val Ala Ser Gly Ala Ser Met Val Pro Ser Glu Thr Asn Pro Phe Gln
155 160 165
gac aac aac tct cac gga act cac gtt gcc ggc aca gtt gcg gct ctt 641
Asp Asn Asn Ser His Gly Thr His Val Ala Gly Thr Val Ala Ala Leu
170 175 180
aat aac tca atc ggt gta tta ggc gtt gcg cca agc gca tca ctt tac 689
Asn Asn Ser Ile Gly Val Leu Gly Val Ala Pro Ser Ala Ser Leu Tyr
185 190 195
gct gta aaa gtt ctc ggt gct gac ggt tcc ggc caa tac agc tgg atc 737
Ala Val Lys Val Leu Gly Ala Asp Gly Ser Gly Gln Tyr Ser Trp Ile
200 205 210
att aac gga atc gag tgg gcg atc gca aac aat atg gac gtt att aac 785
Ile Asn Gly Ile Glu Trp Ala Ile Ala Asn Asn Met Asp Val Ile Asn
215 220 225 230
tg agc ctc ggc gga cct tct ggt tct gct gct tta aaa gcg gca gtt 833
Met Ser Leu Gly Gly Pro Ser Gly Ser Ala Ala Leu Lys Ala Ala Val
235 240 245
gat aaa gcc gtt gca tcc ggc gtc gta gtc gtt gcg gca gcc ggt aac 881
Asp Lys Ala Val Ala Ser Gly Val Val Val Val Ala Ala Ala Gly Asn
250 255 260
gaa ggc act tcc ggc agc tca agc aca gtg ggc tac cct ggt aaa tac 929
Glu Gly Thr Ser Gly Ser Ser Ser Thr Val Gly Tyr Pro Gly Lys Tyr
265 270 275
cct tct gtc att gca gta ggc gct gtt gac agc agc aac caa aga gca 977
Pro Ser Val Ile Ala Val Gly Ala Val Asp Ser Ser Asn Gln Arg Ala
280 285 290
tct ttc tca agc gta gga cct gag ctt gat gtc atg gca cct ggc gta 1025
Ser Phe Ser Ser Val Gly Pro Glu Leu Asp Val Met Ala Pro Gly Val
295 300 305 310
tct atc caa agc acg ctt cct gga aac aaa tac ggg gcg tac aac ggt 1073
Ser Ile Gln Ser Thr Leu Pro Gly Asn Lys Tyr Gly Ala Tyr Asn Gly
315 320 325
acg tca atg gca tct ccg cac gtt gcc gga gcg gct gct ttg att ctt 1121
Thr Ser Met Ala Ser Pro His Val Ala Gly Ala Ala Ala Leu Ile Leu
330 335 340
ct aag cac ccg aac tgg aca aac act caa gtc cgc agc agt tta gaa 1169
Ser Lys His Pro Asn Trp Thr Asn Thr Gln Val Arg Ser Ser Leu Glu
345 350 355
aac acc act aca aaa ctt ggt gat tct ttg tac tat gga aaa ggg ctg 1217
Asn Thr Thr Thr Lys Leu Gly Asp Ser Leu Tyr Tyr Gly Lys Gly Leu
360 365 370
atc aac gta caa gcg gca gct cag taa a acataaaaaa ccggccttgg 1265
Ile Asn Val Gln Ala Ala Ala Gln *
375 380
ccccgccggt tttttattat ttttcttcct ccgcatgttc aatccgctcc ataatcgacg 1325
gatggctccc tctgaaaatt ttaacgagaa acggcgggtt gacccggctc agtcccgtaa 1385
cggccaactc ctgaaacgtc tcaatcgccg cttcccggtt tccggtcagc tcaatgccat 1445
aacggtcggc ggcgttttcc tgataccggg agacggcatt cgtaatcgga tc 1497
2
1497
PRT
B. amyloliquefaciens
2
Gly Gly Thr Cys Thr Ala Cys Thr Ala Ala Ala Ala Thr Ala Thr Thr
1 5 10 15
Ala Thr Thr Cys Cys Ala Thr Ala Cys Thr Ala Thr Ala Cys Ala Ala
20 25 30
Thr Thr Ala Ala Thr Ala Cys Ala Cys Ala Gly Ala Ala Thr Ala Ala
35 40 45
Thr Cys Thr Gly Thr Cys Thr Ala Thr Thr Gly Gly Thr Thr Ala Thr
50 55 60
Thr Cys Thr Gly Cys Ala Ala Ala Thr Gly Ala Ala Ala Ala Ala Ala
65 70 75 80
Ala Gly Gly Ala Gly Ala Gly Gly Ala Thr Ala Ala Ala Gly Ala Gly
85 90 95
Thr Gly Ala Gly Ala Gly Gly Cys Ala Ala Ala Ala Ala Ala Gly Thr
100 105 110
Ala Thr Gly Gly Ala Thr Cys Ala Gly Thr Thr Thr Gly Cys Thr Gly
115 120 125
Thr Thr Thr Gly Cys Thr Thr Thr Ala Gly Cys Gly Thr Thr Ala Ala
130 135 140
Thr Cys Thr Thr Thr Ala Cys Gly Ala Thr Gly Gly Cys Gly Thr Thr
145 150 155 160
Cys Gly Gly Cys Ala Gly Cys Ala Cys Ala Thr Cys Cys Thr Cys Thr
165 170 175
Gly Cys Cys Cys Ala Gly Gly Cys Gly Gly Cys Ala Gly Gly Gly Ala
180 185 190
Ala Ala Thr Cys Ala Ala Ala Cys Gly Gly Gly Gly Ala Ala Ala Ala
195 200 205
Gly Ala Ala Ala Thr Ala Thr Ala Thr Thr Gly Thr Cys Gly Gly Gly
210 215 220
Thr Thr Thr Ala Ala Ala Cys Ala Gly Ala Cys Ala Ala Thr Gly Ala
225 230 235 240
Gly Cys Ala Cys Gly Ala Thr Gly Ala Gly Cys Gly Cys Cys Gly Cys
245 250 255
Thr Ala Ala Gly Ala Ala Gly Ala Ala Ala Gly Ala Thr Gly Thr Cys
260 265 270
Ala Thr Thr Thr Cys Thr Gly Ala Ala Ala Ala Ala Gly Gly Cys Gly
275 280 285
Gly Gly Ala Ala Ala Gly Thr Gly Cys Ala Ala Ala Ala Gly Cys Ala
290 295 300
Ala Thr Thr Cys Ala Ala Ala Thr Ala Thr Gly Thr Ala Gly Ala Cys
305 310 315 320
Gly Cys Ala Gly Cys Thr Thr Cys Ala Gly Thr Cys Ala Cys Ala Thr
325 330 335
Thr Ala Ala Ala Cys Gly Ala Ala Ala Ala Ala Gly Cys Thr Gly Thr
340 345 350
Ala Ala Ala Ala Gly Ala Ala Thr Thr Gly Ala Ala Ala Ala Ala Ala
355 360 365
Gly Ala Cys Cys Cys Gly Ala Gly Cys Gly Thr Cys Gly Cys Thr Thr
370 375 380
Ala Cys Gly Thr Thr Gly Ala Ala Gly Ala Ala Gly Ala Thr Cys Ala
385 390 395 400
Cys Gly Thr Ala Gly Cys Ala Cys Ala Thr Gly Cys Gly Thr Ala Cys
405 410 415
Gly Cys Gly Cys Ala Gly Thr Cys Cys Gly Thr Gly Cys Cys Thr Thr
420 425 430
Ala Cys Gly Gly Cys Gly Thr Ala Thr Cys Ala Cys Ala Ala Ala Thr
435 440 445
Thr Ala Ala Ala Gly Cys Cys Cys Cys Thr Gly Cys Thr Cys Thr Gly
450 455 460
Cys Ala Cys Thr Cys Thr Cys Ala Ala Gly Gly Cys Thr Ala Cys Ala
465 470 475 480
Cys Thr Gly Gly Ala Thr Cys Ala Ala Ala Thr Gly Thr Thr Ala Ala
485 490 495
Ala Gly Thr Ala Gly Cys Gly Gly Thr Thr Ala Thr Cys Gly Ala Cys
500 505 510
Ala Gly Cys Gly Gly Thr Ala Thr Cys Gly Ala Thr Thr Cys Thr Thr
515 520 525
Cys Thr Cys Ala Thr Cys Cys Thr Gly Ala Thr Thr Thr Ala Ala Ala
530 535 540
Gly Gly Thr Ala Gly Cys Ala Ala Gly Cys Gly Gly Ala Gly Cys Cys
545 550 555 560
Ala Gly Cys Ala Thr Gly Gly Thr Thr Cys Cys Thr Thr Cys Thr Gly
565 570 575
Ala Ala Ala Cys Ala Ala Ala Thr Cys Cys Thr Thr Thr Cys Cys Ala
580 585 590
Ala Gly Ala Cys Ala Ala Cys Ala Ala Cys Thr Cys Thr Cys Ala Cys
595 600 605
Gly Gly Ala Ala Cys Thr Cys Ala Cys Gly Thr Thr Gly Cys Cys Gly
610 615 620
Gly Cys Ala Cys Ala Gly Thr Thr Gly Cys Gly Gly Cys Thr Cys Thr
625 630 635 640
Thr Ala Ala Thr Ala Ala Cys Thr Cys Ala Ala Thr Cys Gly Gly Thr
645 650 655
Gly Thr Ala Thr Thr Ala Gly Gly Cys Gly Thr Thr Gly Cys Gly Cys
660 665 670
Cys Ala Ala Gly Cys Gly Cys Ala Thr Cys Ala Cys Thr Thr Thr Ala
675 680 685
Cys Gly Cys Thr Gly Thr Ala Ala Ala Ala Gly Thr Thr Cys Thr Cys
690 695 700
Gly Gly Thr Gly Cys Thr Gly Ala Cys Gly Gly Thr Thr Cys Cys Gly
705 710 715 720
Gly Cys Cys Ala Ala Thr Ala Cys Ala Gly Cys Thr Gly Gly Ala Thr
725 730 735
Cys Ala Thr Thr Ala Ala Cys Gly Gly Ala Ala Thr Cys Gly Ala Gly
740 745 750
Thr Gly Gly Gly Cys Gly Ala Thr Cys Gly Cys Ala Ala Ala Cys Ala
755 760 765
Ala Thr Ala Thr Gly Gly Ala Cys Gly Thr Thr Ala Thr Thr Ala Ala
770 775 780
Cys Ala Thr Gly Ala Gly Cys Cys Thr Cys Gly Gly Cys Gly Gly Ala
785 790 795 800
Cys Cys Thr Thr Cys Thr Gly Gly Thr Thr Cys Thr Gly Cys Thr Gly
805 810 815
Cys Thr Thr Thr Ala Ala Ala Ala Gly Cys Gly Gly Cys Ala Gly Thr
820 825 830
Thr Gly Ala Thr Ala Ala Ala Gly Cys Cys Gly Thr Thr Gly Cys Ala
835 840 845
Thr Cys Cys Gly Gly Cys Gly Thr Cys Gly Thr Ala Gly Thr Cys Gly
850 855 860
Thr Thr Gly Cys Gly Gly Cys Ala Gly Cys Cys Gly Gly Thr Ala Ala
865 870 875 880
Cys Gly Ala Ala Gly Gly Cys Ala Cys Thr Thr Cys Cys Gly Gly Cys
885 890 895
Ala Gly Cys Thr Cys Ala Ala Gly Cys Ala Cys Ala Gly Thr Gly Gly
900 905 910
Gly Cys Thr Ala Cys Cys Cys Thr Gly Gly Thr Ala Ala Ala Thr Ala
915 920 925
Cys Cys Cys Thr Thr Cys Thr Gly Thr Cys Ala Thr Thr Gly Cys Ala
930 935 940
Gly Thr Ala Gly Gly Cys Gly Cys Thr Gly Thr Thr Gly Ala Cys Ala
945 950 955 960
Gly Cys Ala Gly Cys Ala Ala Cys Cys Ala Ala Ala Gly Ala Gly Cys
965 970 975
Ala Thr Cys Thr Thr Thr Cys Thr Cys Ala Ala Gly Cys Gly Thr Ala
980 985 990
Gly Gly Ala Cys Cys Thr Gly Ala Gly Cys Thr Thr Gly Ala Thr Gly
995 1000 1005
Thr Cys Ala Thr Gly Gly Cys Ala Cys Cys Thr Gly Gly Cys Gly Thr
1010 1015 1020
Ala Thr Cys Thr Ala Thr Cys Cys Ala Ala Ala Gly Cys Ala Cys Gly
1025 1030 1035 1040
Cys Thr Thr Cys Cys Thr Gly Gly Ala Ala Ala Cys Ala Ala Ala Thr
1045 1050 1055
Ala Cys Gly Gly Gly Gly Cys Gly Thr Ala Cys Ala Ala Cys Gly Gly
1060 1065 1070
Thr Ala Cys Gly Thr Cys Ala Ala Thr Gly Gly Cys Ala Thr Cys Thr
1075 1080 1085
Cys Cys Gly Cys Ala Cys Gly Thr Thr Gly Cys Cys Gly Gly Ala Gly
1090 1095 1100
Cys Gly Gly Cys Thr Gly Cys Thr Thr Thr Gly Ala Thr Thr Cys Thr
1105 1110 1115 1120
Thr Thr Cys Thr Ala Ala Gly Cys Ala Cys Cys Cys Gly Ala Ala Cys
1125 1130 1135
Thr Gly Gly Ala Cys Ala Ala Ala Cys Ala Cys Thr Cys Ala Ala Gly
1140 1145 1150
Thr Cys Cys Gly Cys Ala Gly Cys Ala Gly Thr Thr Thr Ala Gly Ala
1155 1160 1165
Ala Ala Ala Cys Ala Cys Cys Ala Cys Thr Ala Cys Ala Ala Ala Ala
1170 1175 1180
Cys Thr Thr Gly Gly Thr Gly Ala Thr Thr Cys Thr Thr Thr Gly Thr
1185 1190 1195 1200
Ala Cys Thr Ala Thr Gly Gly Ala Ala Ala Ala Gly Gly Gly Cys Thr
1205 1210 1215
Gly Ala Thr Cys Ala Ala Cys Gly Thr Ala Cys Ala Ala Gly Cys Gly
1220 1225 1230
Gly Cys Ala Gly Cys Thr Cys Ala Gly Thr Ala Ala Ala Ala Cys Ala
1235 1240 1245
Thr Ala Ala Ala Ala Ala Ala Cys Cys Gly Gly Cys Cys Thr Thr Gly
1250 1255 1260
Gly Cys Cys Cys Cys Gly Cys Cys Gly Gly Thr Thr Thr Thr Thr Thr
1265 1270 1275 1280
Ala Thr Thr Ala Thr Thr Thr Thr Thr Cys Thr Thr Cys Cys Thr Cys
1285 1290 1295
Cys Gly Cys Ala Thr Gly Thr Thr Cys Ala Ala Thr Cys Cys Gly Cys
1300 1305 1310
Thr Cys Cys Ala Thr Ala Ala Thr Cys Gly Ala Cys Gly Gly Ala Thr
1315 1320 1325
Gly Gly Cys Thr Cys Cys Cys Thr Cys Thr Gly Ala Ala Ala Ala Thr
1330 1335 1340
Thr Thr Thr Ala Ala Cys Gly Ala Gly Ala Ala Ala Cys Gly Gly Cys
1345 1350 1355 1360
Gly Gly Gly Thr Thr Gly Ala Cys Cys Cys Gly Gly Cys Thr Cys Ala
1365 1370 1375
Gly Thr Cys Cys Cys Gly Thr Ala Ala Cys Gly Gly Cys Cys Ala Ala
1380 1385 1390
Cys Thr Cys Cys Thr Gly Ala Ala Ala Cys Gly Thr Cys Thr Cys Ala
1395 1400 1405
Ala Thr Cys Gly Cys Cys Gly Cys Thr Thr Cys Cys Cys Gly Gly Thr
1410 1415 1420
Thr Thr Cys Cys Gly Gly Thr Cys Ala Gly Cys Thr Cys Ala Ala Thr
1425 1430 1435 1440
Gly Cys Cys Ala Thr Ala Ala Cys Gly Gly Thr Cys Gly Gly Cys Gly
1445 1450 1455
Gly Cys Gly Thr Thr Thr Thr Cys Cys Thr Gly Ala Thr Ala Cys Cys
1460 1465 1470
Gly Gly Gly Ala Gly Ala Cys Gly Gly Cys Ala Thr Thr Cys Gly Thr
1475 1480 1485
Ala Ala Thr Cys Gly Gly Ala Thr Cys
1490 1495
3
275
PRT
B. amyloliquefaciens
3
Ala Gln Ser Val Pro Tyr Gly Val Ser Gln Ile Lys Ala Pro Ala Leu
1 5 10 15
His Ser Gln Gly Tyr Thr Gly Ser Asn Val Lys Val Ala Val Ile Asp
20 25 30
Ser Gly Ile Asp Ser Ser His Pro Asp Leu Lys Val Ala Gly Gly Ala
35 40 45
Ser Met Val Pro Ser Glu Thr Asn Pro Phe Gln Asp Asn Asn Ser His
50 55 60
Gly Thr His Val Ala Gly Thr Val Ala Ala Leu Asn Asn Ser Ile Gly
65 70 75 80
Val Leu Gly Val Ala Pro Ser Ala Ser Leu Tyr Ala Val Lys Val Leu
85 90 95
Gly Ala Asp Gly Ser Gly Gln Tyr Ser Trp Ile Ile Asn Gly Ile Glu
100 105 110
Trp Ala Ile Ala Asn Asn Met Asp Val Ile Asn Met Ser Leu Gly Gly
115 120 125
Pro Ser Gly Ser Ala Ala Leu Lys Ala Ala Val Asp Lys Ala Val Ala
130 135 140
Ser Gly Val Val Val Val Ala Ala Ala Gly Asn Glu Gly Thr Ser Gly
145 150 155 160
Ser Ser Ser Thr Val Gly Tyr Pro Gly Lys Tyr Pro Ser Val Ile Ala
165 170 175
Val Gly Ala Val Asp Ser Ser Asn Gln Arg Ala Ser Phe Ser Ser Val
180 185 190
Gly Pro Glu Leu Asp Val Met Ala Pro Gly Val Ser Ile Gln Ser Thr
195 200 205
Leu Pro Gly Asn Lys Tyr Gly Ala Tyr Asn Gly Thr Ser Met Ala Ser
210 215 220
Pro His Val Ala Gly Ala Ala Ala Leu Ile Leu Ser Lys His Pro Asn
225 230 235 240
Trp Thr Asn Thr Gln Val Arg Ser Ser Leu Glu Asn Thr Thr Thr Lys
245 250 255
Leu Gly Asp Ser Phe Tyr Tyr Gly Lys Gly Leu Ile Asn Val Gln Ala
260 265 270
Ala Ala Gln
275
4
275
PRT
B. subtilis
4
Ala Gln Ser Val Pro Tyr Gly Ile Ser Gln Ile Lys Ala Pro Ala Leu
1 5 10 15
His Ser Gln Gly Tyr Thr Gly Ser Asn Val Lys Val Ala Val Ile Asp
20 25 30
Ser Gly Ile Asp Ser Ser His Pro Asp Leu Asn Val Arg Gly Gly Ala
35 40 45
Ser Phe Val Pro Ser Glu Thr Asn Pro Tyr Gln Asp Gly Ser Ser His
50 55 60
Gly Thr His Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly
65 70 75 80
Val Leu Gly Val Ser Pro Ser Ala Ser Leu Tyr Ala Val Lys Val Leu
85 90 95
Asp Ser Thr Gly Ser Gly Gln Tyr Ser Trp Ile Ile Asn Gly Ile Glu
100 105 110
Trp Ala Ile Ser Asn Asn Met Asp Val Ile Asn Met Ser Leu Gly Gly
115 120 125
Pro Thr Gly Ser Thr Ala Leu Lys Thr Val Val Asp Lys Ala Val Ser
130 135 140
Ser Gly Ile Val Val Ala Ala Ala Ala Gly Asn Glu Gly Ser Ser Gly
145 150 155 160
Ser Thr Ser Thr Val Gly Tyr Pro Ala Lys Tyr Pro Ser Thr Ile Ala
165 170 175
Val Gly Ala Val Asn Ser Ser Asn Gln Arg Ala Ser Phe Ser Ser Ala
180 185 190
Gly Ser Glu Leu Asp Val Met Ala Pro Gly Val Ser Ile Gln Ser Thr
195 200 205
Leu Pro Gly Gly Thr Tyr Gly Ala Tyr Asn Gly Thr Ser Met Ala Thr
210 215 220
Pro His Val Ala Gly Ala Ala Ala Leu Ile Leu Ser Lys His Pro Thr
225 230 235 240
Trp Thr Asn Ala Gln Val Arg Asp Arg Leu Glu Ser Thr Ala Thr Tyr
245 250 255
Leu Gly Asn Ser Phe Tyr Tyr Gly Lys Gly Leu Ile Asn Val Gln Ala
260 265 270
Ala Ala Gln
275
5
274
PRT
B. licheniformis
5
Ala Gln Thr Val Pro Tyr Gly Ile Pro Leu Ile Lys Ala Asp Lys Val
1 5 10 15
Gln Ala Gln Gly Phe Lys Gly Ala Asn Val Lys Val Ala Val Leu Asp
20 25 30
Thr Gly Ile Gln Ala Ser His Pro Asp Leu Asn Val Val Gly Gly Ala
35 40 45
Ser Phe Val Ala Gly Glu Ala Tyr Asn Thr Asp Gly Asn Gly His Gly
50 55 60
Thr His Val Ala Gly Thr Val Ala Ala Leu Asp Asn Thr Thr Gly Val
65 70 75 80
Leu Gly Val Ala Pro Ser Val Ser Leu Tyr Ala Val Lys Val Leu Asn
85 90 95
Ser Ser Gly Ser Gly Ser Tyr Ser Gly Ile Val Ser Gly Ile Glu Trp
100 105 110
Ala Thr Thr Asn Gly Met Asp Val Ile Asn Met Ser Leu Gly Gly Ala
115 120 125
Ser Gly Ser Thr Ala Met Lys Gln Ala Val Asp Asn Ala Tyr Ala Arg
130 135 140
Gly Val Val Val Val Ala Ala Ala Gly Asn Ser Gly Asn Ser Gly Ser
145 150 155 160
Thr Asn Thr Ile Gly Tyr Pro Ala Lys Tyr Asp Ser Val Ile Ala Val
165 170 175
Gly Ala Val Asp Ser Asn Ser Asn Arg Ala Ser Phe Ser Ser Val Gly
180 185 190
Ala Glu Leu Glu Val Met Ala Pro Gly Ala Gly Val Tyr Ser Thr Tyr
195 200 205
Pro Thr Asn Thr Tyr Ala Thr Leu Asn Gly Thr Ser Met Ala Ser Pro
210 215 220
His Val Ala Gly Ala Ala Ala Leu Ile Leu Ser Lys His Pro Asn Leu
225 230 235 240
Ser Ala Ser Gln Val Arg Asn Arg Leu Ser Ser Thr Ala Thr Tyr Leu
245 250 255
Gly Ser Ser Phe Tyr Tyr Gly Lys Gly Leu Ile Asn Val Glu Ala Ala
260 265 270
Ala Gln
6
269
PRT
B. lentus
6
Ala Gln Ser Val Pro Trp Gly Ile Ser Arg Val Gln Ala Pro Ala Ala
1 5 10 15
His Asn Arg Gly Leu Thr Gly Ser Gly Val Lys Val Ala Val Leu Asp
20 25 30
Thr Gly Ile Ser Thr His Pro Asp Leu Asn Ile Arg Gly Gly Ala Ser
35 40 45
Phe Val Pro Gly Glu Pro Ser Thr Gln Asp Gly Asn Gly His Gly Thr
50 55 60
His Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly Val Leu
65 70 75 80
Gly Val Ala Pro Ser Ala Glu Leu Tyr Ala Val Lys Val Leu Gly Ala
85 90 95
Ser Gly Ser Gly Ser Val Ser Ser Ile Ala Gln Gly Leu Glu Trp Ala
100 105 110
Gly Asn Asn Gly Met His Val Ala Asn Leu Ser Leu Gly Ser Pro Ser
115 120 125
Pro Ser Ala Thr Leu Glu Gln Ala Val Asn Ser Ala Thr Ser Arg Gly
130 135 140
Val Leu Val Val Ala Ala Ser Gly Asn Ser Gly Ala Gly Ser Ile Ser
145 150 155 160
Tyr Pro Ala Arg Tyr Ala Asn Ala Met Ala Val Gly Ala Thr Asp Gln
165 170 175
Asn Asn Asn Arg Ala Ser Phe Ser Gln Tyr Gly Ala Gly Leu Asp Ile
180 185 190
Val Ala Pro Gly Val Asn Val Gln Ser Thr Tyr Pro Gly Ser Thr Tyr
195 200 205
Ala Ser Leu Asn Gly Thr Ser Met Ala Thr Pro His Val Ala Gly Ala
210 215 220
Ala Ala Leu Val Lys Gln Lys Asn Pro Ser Trp Ser Asn Val Gln Ile
225 230 235 240
Arg Asn His Leu Lys Asn Thr Ala Thr Ser Leu Gly Ser Thr Asn Leu
245 250 255
Tyr Gly Ser Gly Leu Val Asn Ala Glu Ala Ala Thr Arg
260 265
7
1052
PRT
Homo sapien
7
Met Lys Leu Val Asn Ile Trp Leu Leu Leu Leu Val Val Leu Leu Cys
1 5 10 15
Gly Lys Lys His Leu Gly Asp Arg Leu Glu Lys Lys Ser Phe Glu Lys
20 25 30
Ala Pro Cys Pro Gly Cys Ser His Leu Thr Leu Lys Val Glu Phe Ser
35 40 45
Ser Thr Val Val Glu Tyr Glu Tyr Ile Val Ala Phe Asn Gly Tyr Phe
50 55 60
Thr Ala Lys Ala Arg Asn Ser Phe Ile Ser Ser Ala Leu Lys Ser Ser
65 70 75 80
Glu Val Asp Asn Trp Arg Ile Ile Pro Arg Asn Asn Pro Ser Ser Asp
85 90 95
Tyr Pro Ser Asp Phe Glu Val Ile Gln Ile Lys Glu Lys Gln Lys Ala
100 105 110
Gly Leu Leu Thr Leu Glu Asp His Pro Asn Ile Lys Arg Val Thr Pro
115 120 125
Gln Arg Lys Val Phe Arg Ser Leu Lys Tyr Ala Glu Ser Asp Pro Thr
130 135 140
Val Pro Cys Asn Glu Thr Arg Trp Ser Gln Lys Trp Gln Ser Ser Arg
145 150 155 160
Pro Leu Arg Arg Ala Ser Leu Ser Leu Gly Ser Gly Phe Trp His Ala
165 170 175
Thr Gly Arg His Ser Ser Arg Arg Leu Leu Arg Ala Ile Pro Arg Gln
180 185 190
Val Ala Gln Thr Leu Gln Ala Asp Val Leu Trp Gln Met Gly Tyr Thr
195 200 205
Gly Ala Asn Val Arg Val Ala Val Phe Asp Thr Gly Leu Ser Glu Lys
210 215 220
His Pro His Phe Lys Asn Val Lys Glu Arg Thr Asn Trp Thr Asn Glu
225 230 235 240
Arg Thr Leu Asp Asp Gly Leu Gly His Gly Thr Phe Val Ala Gly Val
245 250 255
Ile Ala Ser Met Arg Glu Cys Gln Gly Phe Ala Pro Asp Ala Glu Leu
260 265 270
His Ile Phe Arg Val Phe Thr Asn Asn Gln Val Ser Tyr Thr Ser Trp
275 280 285
Phe Leu Asp Ala Phe Asn Tyr Ala Ile Leu Lys Lys Ile Asp Val Leu
290 295 300
Asn Leu Ser Ile Gly Gly Pro Asp Phe Met Asp His Pro Phe Val Asp
305 310 315 320
Lys Val Trp Glu Leu Thr Ala Asn Asn Val Ile Met Val Ser Ala Ile
325 330 335
Gly Asn Asp Gly Pro Leu Tyr Gly Thr Leu Asn Asn Pro Ala Asp Gln
340 345 350
Met Asp Val Ile Gly Val Gly Gly Ile Asp Phe Glu Asp Asn Ile Ala
355 360 365
Arg Phe Ser Ser Arg Gly Met Thr Thr Trp Glu Leu Pro Gly Gly Tyr
370 375 380
Gly Arg Met Lys Pro Asp Ile Val Thr Tyr Gly Ala Gly Val Arg Gly
385 390 395 400
Ser Gly Val Lys Gly Gly Cys Arg Ala Leu Ser Gly Thr Ser Val Ala
405 410 415
Ser Pro Val Val Ala Gly Ala Val Thr Leu Leu Val Ser Thr Val Gln
420 425 430
Lys Arg Glu Leu Val Asn Pro Ala Ser Met Lys Gln Ala Leu Ile Ala
435 440 445
Ser Ala Arg Arg Leu Pro Gly Val Asn Met Phe Glu Gln Gly His Gly
450 455 460
Lys Leu Asp Leu Leu Arg Ala Tyr Gln Ile Leu Asn Ser Tyr Lys Pro
465 470 475 480
Gln Ala Ser Leu Ser Pro Ser Tyr Ile Asp Leu Thr Glu Cys Pro Tyr
485 490 495
Met Trp Pro Tyr Cys Ser Gln Pro Ile Tyr Tyr Gly Gly Met Pro Thr
500 505 510
Val Val Asn Val Thr Ile Leu Asn Gly Met Gly Val Thr Gly Arg Ile
515 520 525
Val Asp Lys Pro Asp Trp Gln Pro Tyr Leu Pro Gln Asn Gly Asp Asn
530 535 540
Ile Glu Val Ala Phe Ser Tyr Ser Ser Val Leu Trp Pro Trp Ser Gly
545 550 555 560
Tyr Leu Ala Ile Ser Ile Ser Val Thr Lys Lys Ala Ala Ser Trp Glu
565 570 575
Gly Ile Ala Gln Gly His Val Met Ile Thr Val Ala Ser Pro Ala Glu
580 585 590
Thr Glu Ser Lys Asn Gly Ala Glu Gln Thr Ser Thr Val Lys Leu Pro
595 600 605
Ile Lys Val Lys Ile Ile Pro Thr Pro Pro Arg Ser Lys Arg Val Leu
610 615 620
Trp Asp Gln Tyr His Asn Leu Arg Tyr Pro Pro Gly Tyr Phe Pro Arg
625 630 635 640
Asp Asn Leu Arg Met Lys Asn Asp Pro Leu Asp Trp Asn Gly Asp His
645 650 655
Ile His Thr Asn Phe Arg Asp Met Tyr Gln His Leu Arg Ser Met Gly
660 665 670
Tyr Phe Val Glu Val Leu Gly Ala Pro Phe Thr Cys Phe Asp Ala Ser
675 680 685
Gln Tyr Gly Thr Leu Leu Met Val Asp Ser Glu Glu Glu Tyr Phe Pro
690 695 700
Glu Glu Ile Ala Lys Leu Arg Arg Asp Val Asp Asn Gly Leu Ser Leu
705 710 715 720
Val Ile Phe Ser Asp Trp Tyr Asn Thr Ser Val Met Arg Lys Val Lys
725 730 735
Phe Tyr Asp Glu Asn Thr Arg Gln Trp Trp Met Pro Asp Thr Gly Gly
740 745 750
Ala Asn Ile Pro Ala Leu Asn Glu Leu Leu Ser Val Trp Asn Met Gly
755 760 765
Phe Ser Asp Gly Leu Tyr Glu Gly Glu Phe Thr Leu Ala Asn His Asp
770 775 780
Met Tyr Tyr Ala Ser Gly Cys Ser Ile Ala Lys Phe Pro Glu Asp Gly
785 790 795 800
Val Val Ile Thr Gln Thr Phe Lys Asp Gln Gly Leu Glu Val Leu Lys
805 810 815
Gln Glu Thr Ala Val Val Glu Asn Val Pro Ile Leu Gly Leu Tyr Gln
820 825 830
Ile Pro Ala Glu Gly Gly Gly Arg Ile Val Leu Tyr Gly Asp Ser Asn
835 840 845
Cys Leu Asp Asp Ser His Arg Gln Lys Asp Cys Phe Trp Leu Leu Asp
850 855 860
Ala Leu Leu Gln Tyr Thr Ser Tyr Gly Val Thr Pro Pro Ser Leu Ser
865 870 875 880
His Ser Gly Asn Arg Gln Arg Pro Pro Ser Gly Ala Gly Ser Val Thr
885 890 895
Pro Glu Arg Met Glu Gly Asn His Leu His Arg Tyr Ser Lys Val Leu
900 905 910
Glu Ala His Leu Gly Asp Pro Lys Pro Arg Pro Leu Pro Ala Cys Pro
915 920 925
Arg Leu Ser Trp Ala Lys Pro Gln Pro Leu Asn Glu Thr Ala Pro Ser
930 935 940
Asn Leu Trp Lys His Gln Lys Leu Leu Ser Ile Asp Leu Asp Lys Val
945 950 955 960
Val Leu Pro Asn Phe Arg Ser Asn Arg Pro Gln Val Arg Pro Leu Ser
965 970 975
Pro Gly Glu Ser Gly Ala Trp Asp Ile Pro Gly Gly Ile Met Pro Gly
980 985 990
Arg Tyr Asn Gln Glu Val Gly Gln Thr Ile Pro Val Phe Ala Phe Leu
995 1000 1005
Gly Ala Met Val Val Leu Ala Phe Phe Val Val Gln Ile Asn Lys Ala
1010 1015 1020
Lys Ser Arg Pro Lys Arg Arg Lys Pro Arg Val Lys Arg Pro Gln Leu
1025 1030 1035 1040
Met Gln Gln Val His Pro Pro Lys Thr Pro Ser Val
1045 1050 | The present invention relates to a method of producing novel improved protein mutant which produce low allergenic response in humans compared to the parent of that mutant. Specifically, the present invention comprises neutralizing or reducing the allergenicity of a protein by introducing therein as replacement or modification of an epitope on such protein a sequence from human subtilisin. | 2 |
BACKGROUND OF THE INVENTION
[0001] The present invention is in the field of electrical generators and motors and, more particularly, electrical starter generators operating at very high rotational speeds.
[0002] In certain applications of generators such as those employed in aircraft, there is a requirement to produce a high power density with a generator that is small in size and light in weight. In these applications, a desired high power density may be achieved with relatively small generators which operate at very high rotational speeds. A typical aircraft generator may operate at rotational speeds of 12,000 to 24,000 rpm.
[0003] When a generator is operated at such high rotational speeds, rotatable components of the generator may be subjected to correspondingly high centrifugal forces. Some rotatable components may be particularly vulnerable to damage from centrifugal forces and fatigue. Examples of these vulnerable components are interconnections between field coils of the generators.
[0004] In a typical aircraft high-speed generator, field coils may be interconnected to one another with crossovers. Fatigue inducing stresses may arise in crossovers because high rotational speeds and temperatures of the aircraft generators produce a radial displacement of the field coils relative to an axis of rotation. This radial displacement may cause variation of circumferential spacing between the field coils. While such spacing variation may be relatively small, it is nevertheless large enough to produce bending of the crossover during each change of rotational speed of the generator. Repeated bending of the flat strip crossovers may produce stresses which may lead to fatigue failure of the crossovers.
[0005] As can be seen, it would be desirable to construct high-speed generators which do not incorporate crossovers that are vulnerable to fatigue failure. Additionally, it would be desirable to provide a method for constructing such generators without producing work hardening of the crossover or wicking of brazing filler metal into the crossover.
SUMMARY OF THE INVENTION
[0006] In one aspect of the present invention a generator comprises at least a first and at least a second field coil adapted to rotate around an axis. The first and second field coils each comprise wound flat conductors. The first and second field coils are interconnected electrically in series by a crossover attached to the flat conductors of both of the field coils. The crossover comprises a flexible interconnecting member. The flexible interconnecting member has at least a first and at least a second attachment member attached thereto. The flat conductor of the first field coil is attached to the first attachment member and the flat conductor of the second field coil is attached to the second attachment member.
[0007] In another aspect of the present invention a crossover for electrically interconnecting field coils in a generator comprises a flat braided wire member having two ends and flat metal strips attached to the ends of the braided wire member.
[0008] In still another aspect of the present invention a method for producing electrical current with a high-speed electrical generator comprises the steps of, passing electrical current through at least a first and at least a second field coil, passing electrical current between the first and the second field coil on an electrically conductive crossover, rotating the field coils about an axis while producing centrifugal force on the field coils which results in a variation of circumferential spacing between the field coils and allowing the crossover to flex during the variation in circumferential displacement so that fatigue inducing stress is not produced in the crossover.
[0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is partial cross-sectional perspective view of a generator constructed in accordance with the invention;
[0011] FIG. 2 is a perspective view of a field coil of the generator of FIG. 1 in accordance with the invention;
[0012] FIG. 3 is a schematic view of interconnections between field coils of the generator of FIG. 1 in accordance with the invention;
[0013] FIG. 4 is a perspective view of a portion of the generator of FIG. 1 showing a crossover in accordance with the invention;
[0014] FIG. 5 is a partial perspective view of the generator of FIG. 1 showing interconnected field coils in accordance with the invention;
[0015] FIG. 5A is a detailed view of the portion of the generator of FIG. 5 in accordance with the present invention; and
[0016] FIG. 6 is a detailed view of a portion of the generator of FIG. 1 showing an inner crossover in accordance with the present invention;
[0017] FIG. 7 is a perspective view of a crossover in accordance with the invention;
[0018] FIG. 7A is a detailed view of a portion of the crossover of FIG. 7 in accordance with the invention;
[0019] FIG. 8 is an illustration of a technique for brazing the crossover of FIG. 7 in accordance with the invention;
[0020] FIG. 9 is a schematic view of a crossover attachment to field coils in accordance with the invention;
[0021] FIG. 9A is a detailed view of a portion of the crossover attachment of FIG. 9 in accordance with the invention; and
[0022] FIG. 10 is a flow chart of a method of generating electric power in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0024] Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any of the problems discussed above or may only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below.
[0025] Broadly, embodiments of the present invention may be useful in improving high-speed electrical generators. More particularly, embodiments of the present invention may provide a simple expedient to reduce damage from radial displacement of field coils resulting from centrifugal forces. Embodiments of the present invention may be particularly useful in aircraft generators which operate at high rotational speeds of up to about 24,000 rpm.
[0026] An embodiment of the present invention may provide a generator that is constructed with crossovers that may be produced as sub-assemblies and then inserted into the generator. The embodiment of the present invention may use a sub-assembly that incorporates a flexible braided wire member as a crossover. The embodiment of the present invention may comprise a unique construction technique which may preclude wicking of brazing filler metal into the braided wire member thus keeping the crossover flexible so that a resultant crossover may be provided with a reduced susceptibility to fatigue failure. These desirable improvements of a high-speed generator may be achieved by constructing a generator in an inventive configuration illustrated in FIG. 1 .
[0027] Referring now to FIGS. 1 and 2 , a generator, shown symbolically and designated generally by the numeral 10 , may be comprised of field coils 12 which may be assembled in a rotor 14 adapted for rotation about an axis 16 . The generator 10 may also comprise an exciter assembly 17 . The generator may be constructed with a plurality of field coils electrically interconnected in series. The field coils 12 may be comprised of a tightly wound conductor 18 which may have a generally flat configuration such as that illustrated in FIG. 2 .
[0028] Referring now to FIGS. 3 through FIG. 6 , an illustrative embodiment of the present inventive generator 10 may comprise four of the field coils 12 interconnected with one another. Interconnection between the field coils 12 may be provided with outer crossovers 20 and inner crossovers 22 . The outer crossovers 20 may be attached to outer sides 12 - 1 of the field coils 12 . The inner crossovers 22 may be attached to inner sides 12 - 2 of the field coils 12 . FIGS. 4 , 5 and 5 A illustrate locations of the outer crossovers 20 . FIG. 6 illustrates a location of one of the inner crossovers 22 .
[0029] Referring now to FIGS. 7 and 7A , one of the outer crossovers 20 is shown in detail. While FIG. 7 shows construction of one of the outer crossovers 20 , it should be noted that the inner crossovers 22 may be constructed in a similar manner. The outer crossover 20 may comprise a sub-assembly of attachment leads 20 - 1 and an interconnection member 20 - 2 . The attachment leads 20 - 1 may be constructed from flat meta; strip such as annealed copper. The interconnection member 20 - 2 may comprise braided wire. The attachment leads 20 - 1 may be connected to the interconnection member 20 - 2 with a brazed connection 20 - 3 that employs a brazing filler metal 20 - 4 . A flexible portion 20 - 5 of the crossover 20 may be located between the brazed connections 20 - 3 . The brazed connection 20 - 3 may be referred to as crossover-subassembly brazed connection because it may be produced while the crossover 20 is being constructed as a subassembly which may be subsequently assembled into the generator 10 .
[0030] Referring now to FIG. 8 it may be seen that the crossover-subassembly brazed connection 20 - 3 may be produced without allowing any wicking of brazing filler metal 20 - 4 into the flexible portion 20 - 5 of the outer crossover 20 . This desirable prevention of wicking may be achieved by immersing the flexible portion 20 - 5 in a cooling fluid 30 while heat may be applied to the attachment lead 20 - 1 during brazing. The cooling fluid 30 may keep the flexible portion 20 - 5 at a temperature below a melting temperature of the brazing filler metal 20 - 4 . Thus, the brazing filler metal 20 - 4 may not wick into the flexible portion 20 - 5 of the crossover 20 . Consequently, a resultant one of the crossovers 20 may be produced with desirable flexibility.
[0031] Referring now to FIGS. 9 and 9A , it may be seen that the generator 10 of FIG. 1 may be produced by brazing the crossovers 20 to the field coils 12 . In FIGS. 9 and 9A , a simplified example of construction of the generator of FIG. 1 is illustrated. Only one of the crossovers 20 is shown interconnecting only two of the field coils 12 . It may be seen that crossover-attaching brazed connections 40 may be produced with crossover-attaching brazing filler metal 40 - 1 . It may also be seen that application of heat to melt the filler metal 40 - 1 may not result in melting of the filler metal 20 - 4 of FIG. 7 . Thus the coils 12 may be interconnected without a resultant wicking of either the filler metal 40 - 1 or the filler metal 20 - 4 into the flexible portion 20 - 5 of the crossover 20 . In other words, brazing metal wicking may not produce undesirable rigidity in the flexible portion 20 - 5 of the crossover 20 . Consequently, the coils 12 may be interconnected with a flexible interconnection that may be resistant to fatigue inducing stress. In other words fatigue inducing stress that might otherwise result from multiple changes of rotational speed of the rotor 14 (see FIG. 1 ) may be avoided.
[0032] In one embodiment of the present invention, a method is provided for producing electrical current with a high speed generator (e.g. the generator 1 0 ). In that regard the method may be understood by referring to FIG. 11 . In FIG. 11 , a flow chart portrays various aspects of an inventive method 100 . In a step 102 , current may be passed through a first field coil (e.g., one of the field coils 12 ). In a step 104 , current may be passed from a first field coil to a second field coil through a flexible crossover (e.g., current may pass through the crossover 20 from one of the field coils 12 to another one of the field coils 12 ). In a step 106 , current may be passed through a second field coil (e.g., one of the field coils 12 ). In a step 108 , a magnetic field may be produced (e.g. by passage of current through the field coils 12 ). In a step 110 , the field coils may be rotated about an axis (e.g., the field coils 12 may be rotated about the axis 16 by rotation of the rotor 14 ). In a step 112 , the crossover may be allowed to flex to compensate for relative displacement of the field coils as a result of centrifugal force produced by rotation in the step 110 (e.g., the flexible portion 20 - 5 of the crossover 20 may flex). In a resultant step 114 electrical power may be produced. Thus when the steps of the method 100 are practiced, the generator may operate with multiple variations of rotational speed without producing fatigue inducing stress in the crossover.
[0033] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A high speed aircraft generator may utilize a prefabricated crossover subassembly to interconnect field coils. The crossover may include two attachment leads interconnected with a section of braided wire. The braided wire may remain free of brazing filler metal after the crossover subassembly is brazed into position between field coils of the generator. Consequently, the crossover may remain flexible and may have reduced susceptibility to fatigue failure that may otherwise result from circumferential relative displacement of the field coils from one another during changes of rotational speed of the field coils. | 8 |
REFERENCE TO RELATED APPLICATIONS
This application claims an invention which was disclosed in Provisional Application Number 60/374,165, filed Apr. 19, 2002, entitled “Air Venting Mechanism for Variable Camshaft Timing Devices”. The benefit under 35 USC §119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the field of Variable Camshaft Timing (VCT). More particularly, the invention pertains to air venting mechanism for variable camshaft timing devices.
2. Description of Related Art
The performance of an internal combustion engine can be improved by the use of dual camshafts, one to operate the intake valves of the various cylinders of the engine and the other to operate the exhaust valves. Typically, one of such camshafts is driven by the crankshaft of the engine, through a sprocket and chain drive or a belt drive, and the other of such camshafts is driven by the first, through a second sprocket and chain drive or a second belt drive. Alternatively, both of the camshafts can be driven by a single crankshaft powered chain drive or belt drive. Engine performance in an engine with dual camshafts can be further improved, in terms of idle quality, fuel economy, reduced emissions or increased torque, by changing the positional relationship of one of the camshafts, usually the camshaft which operates the intake valves of the engine, relative to the other camshaft and relative to the crankshaft, to thereby vary the timing of the engine in terms of the operation of intake valves relative to its exhaust valves or in terms of the operation of its valves relative to the position of the crankshaft.
Consideration of information disclosed by the following U.S. patents, which are all hereby incorporated by reference, is useful when exploring the background of the present invention.
U.S. Pat. No. 5,002,023 describes a VCT system within the field of the invention in which the system hydraulics includes a pair of oppositely acting hydraulic cylinders with appropriate hydraulic flow elements to selectively transfer hydraulic fluid from one of the cylinders to the other, or vice versa, to thereby advance or retard the circumferential position on of a camshaft relative to a crankshaft. The control system utilizes a control valve in which the exhaustion of hydraulic fluid from one or another of the oppositely acting cylinders is permitted by moving a spool within the valve one way or another from its centered or null position. The movement of the spool occurs in response to an increase or decrease in control hydraulic pressure, P C , on one end of the spool and the relationship between the hydraulic force on such end and an oppositely direct mechanical force on the other end which results from a compression spring that acts thereon.
U.S. Pat. No. 5,107,804 describes an alternate type of VCT system within the field of the invention in which the system hydraulics include a vane having lobes within an enclosed housing which replace the oppositely acting cylinders disclosed by the aforementioned U.S. Pat. No. 5,002,023. The vane is oscillatable with respect to the housing, with appropriate hydraulic flow elements to transfer hydraulic fluid within the housing from one side of a lobe to the other, or vice versa, to thereby oscillate the vane with respect to the housing in one direction or the other, an action which is effective to advance or retard the position of the camshaft relative to the crankshaft. The control system of this VCT system is identical to that divulged in U.S. Pat. No. 5,002,023, using the same type of spool valve responding to the same type of forces acting thereon.
U.S. Pat. Nos. 5,172,659 and 5,184,578 both address the problems of the aforementioned types of VCT systems created by the attempt to balance the hydraulic force exerted against one end of the spool and the mechanical force exerted against the other end. The improved control system disclosed in both U.S. Pat. Nos. 5,172,659 and 5,184,578 utilizes hydraulic force on both ends of the spool. The hydraulic force on one end results from the directly applied hydraulic fluid from the engine oil gallery at full hydraulic pressure, P S . The hydraulic force on the other end of the spool results from a hydraulic cylinder or other force multiplier which acts thereon in response to system hydraulic fluid at reduced pressure, P C , from a PWM solenoid. Because the force at each of the opposed ends of the spool is hydraulic in origin, based on the same hydraulic fluid, changes in pressure or viscosity of the hydraulic fluid will be self-negating, and will not affect the centered or null position of the spool.
U.S. Pat. No. 5,289,805 provides an improved VCT method which utilizes a hydraulic PWM spool position control and an advanced control algorithm that yields a prescribed set point tracking behavior with a high degree of robustness.
In U.S. Pat. No. 5,361,735, a camshaft has a vane secured to an end for non-oscillating rotation. The camshaft also carries a timing belt driven pulley which can rotate with the camshaft but which is oscillatable with respect to the camshaft. The vane has opposed lobes which are received in opposed recesses, respectively, of the pulley. The camshaft tends to change in reaction to torque pulses which it experiences during its normal operation and it is permitted to advance or retard by selectively blocking or permitting the flow of engine oil from the recesses by controlling the position of a spool within a valve body of a control valve in response to a signal from an engine control unit. The spool is urged in a given direction by rotary linear motion translating means which is rotated by an electric motor, preferably of the stepper motor type.
U.S. Pat. No. 5,497,738 shows a control system which eliminates the hydraulic force on one end of a spool resulting from directly applied hydraulic fluid from the engine oil gallery at full hydraulic pressure, P S , utilized by previous embodiments of the VCT system. The force on the other end of the vented spool results from an electromechanical actuator, preferably of the variable force solenoid type, which acts directly upon the vented spool in response to an electronic signal issued from an engine control unit (“ECU”) which monitors various engine parameters. The ECU receives signals from sensors corresponding to camshaft and crankshaft positions and utilizes this information to calculate a relative phase angle. A closed-loop feedback system which corrects for any phase angle error is preferably employed. The use of a variable force solenoid solves the problem of sluggish dynamic response. Such a device can be designed to be as fast as the mechanical response of the spool valve, and certainly much faster than the conventional (fully hydraulic) differential pressure control system. The faster response allows the use of increased closed-loop gain, making the system less sensitive to component tolerances and operating environment.
U.S. Pat. No. 5,657,725 shows a control system which utilizes engine oil pressure for actuation. The system includes A camshaft has a vane secured to an end thereof for non-oscillating rotation therewith. The camshaft also carries a housing which can rotate with the camshaft but which is oscillatable with the camshaft. The vane has opposed lobes which are received in opposed recesses, respectively, of the housing. The recesses have greater circumferential extent than the lobes to permit the vane and housing to oscillate with respect to one another, and thereby permit the camshaft to change in phase relative to a crankshaft. The camshaft tends to change direction in reaction to engine oil pressure and/or camshaft torque pulses which it experiences during its normal operation, and it is permitted to either advance or retard by selectively blocking or permitting the flow of engine oil through the return lines from the recesses by controlling the position of a spool within a spool valve body in response to a signal indicative of an engine operating condition from an engine control unit. The spool is selectively positioned by controlling hydraulic loads on its opposed end in response to a signal from an engine control unit. The vane can be biased to an extreme position to provide a counteractive force to a unidirectionally acting frictional torque experienced by the camshaft during rotation.
U.S. Pat. No. 6,247,434 shows a multi-position variable camshaft timing system actuated by engine oil. Within the system, a hub is secured to a camshaft for rotation synchronous with the camshaft, and a housing circumscribes the hub and is rotatable with the hub and the camshaft and is further oscillatable with respect to the hub and the camshaft within a predetermined angle of rotation. Driving vanes are radially disposed within the housing and cooperate with an external surface on the hub, while driven vanes are radially disposed in the hub and cooperate with an internal surface of the housing. A locking device, reactive to oil pressure, prevents relative motion between the housing and the hub. A controlling device controls the oscillation of the housing relative to the hub.
U.S. Pat. No. 6,250,265 shows a variable valve timing system with actuator locking for internal combustion engine. The system comprising a variable camshaft timing system comprising a camshaft with a vane secured to the camshaft for rotation with the camshaft but not for oscillation with respect to the camshaft. The vane has a circumferentially extending plurality of lobes projecting radially outwardly therefrom and is surrounded by an annular housing that has a corresponding plurality of recesses each of which receives one of the lobes and has a circumferential extent greater than the circumferential extent of the lobe received therein to permit oscillation of the housing relative to the vane and the camshaft while the housing rotates with the camshaft and the vane. Oscillation of the housing relative to the vane and the camshaft is actuated by pressurized engine oil in each of the recesses on opposed sides of the lobe therein, the oil pressure in such recess being preferably derived in part from a torque pulse in the camshaft as it rotates during its operation. An annular locking plate is positioned coaxially with the camshaft and the annular housing and is moveable relative to the annular housing along a longitudinal central axis of the camshaft between a first position, where the locking plate engages the annular housing to prevent its circumferential movement relative to the vane and a second position where circumferential movement of the annular housing relative to the vane is permitted. The locking plate is biased by a spring toward its first position and is urged away from its first position toward its second position by engine oil pressure, to which it is exposed by a passage leading through the camshaft, when engine oil pressure is sufficiently high to overcome the spring biasing force, which is the only time when it is desired to change the relative positions of the annular housing and the vane. The movement of the locking plate is controlled by an engine electronic control unit either through a closed loop control system or an open loop control system.
U.S. Pat. No. 6,263,846 shows a control valve strategy for vane-type variable camshaft timing system. The strategy involves an internal combustion engine that includes a camshaft and hub secured to the camshaft for rotation therewith, where a housing circumscribes the hub and is rotatable with the hub and the camshaft, and is further oscillatable with respect to the hub and camshaft. Driving vanes are radially inwardly disposed in the housing and cooperate with the hub, while driven vanes are radially outwardly disposed in the hub to cooperate with the housing and also circumferentially alternate with the driving vanes to define circumferentially alternating advance and retard chambers. A configuration for controlling the oscillation of the housing relative to the hub includes an electronic engine control unit, and an advancing control valve that is responsive to the electronic engine control unit and that regulates engine oil pressure to and from the advance chambers. A retarding control valve responsive to the electronic engine control unit regulates engine oil pressure to and from the retard chambers. An advancing passage communicates engine oil pressure between the advancing control valve and the advance chambers, while a retarding passage communicates engine oil pressure between the retarding control valve and the retard chambers.
U.S. Pat. No. 6,311,655 shows multi-position variable cam timing system having a vane-mounted locking-piston device. An internal combustion engine having a camshaft and variable camshaft timing system, wherein a rotor is secured to the camshaft and is rotatable but non-oscillatable with respect to the camshaft is described. A housing circumscribes the rotor, is rotatable with both the rotor and the camshaft, and is further oscillatable with respect to both the rotor and the camshaft between a fully retarded position and a fully advanced position. A locking configuration prevents relative motion between the rotor and the housing, and is mounted within either the rotor or the housing, and is respectively and releasably engageable with the other of either the rotor and the housing in the fully retarded position, the fully advanced position, and in positions therebetween. The locking device includes a locking piston having keys terminating one end thereof, and serrations mounted opposite the keys on the locking piston for interlocking the rotor to the housing. A controlling configuration controls oscillation of the rotor relative to the housing.
U.S. Pat. No. 6,374,787 shows a multi-position variable camshaft timing system actuated by engine oil pressure. A hub is secured to a camshaft for rotation synchronous with the camshaft, and a housing circumscribes the hub and is rotatable with the hub and the camshaft and is further oscillatable with respect to the hub and the camshaft within a predetermined angle of rotation. Driving vanes are radially disposed within the housing and cooperate with an external surface on the hub, while driven vanes are radially disposed in the hub and cooperate with an internal surface of the housing. A locking device, reactive to oil pressure, prevents relative motion between the housing and the hub. A controlling device controls the oscillation of the housing relative to the hub.
U.S. Pat. No. 6,477,999 shows a camshaft that has a vane secured to an end thereof for non-oscillating rotation therewith. The camshaft also carries a sprocket that can rotate with the camshaft but is oscillatable with respect to the camshaft. The vane has opposed lobes that are received in opposed recesses, respectively, of the sprocket. The recesses have greater circumferential extent than the lobes to permit the vane and sprocket to oscillate with respect to one another. The camshaft phase tends to change in reaction to pulses that it experiences during its normal operation, and it is permitted to change only in a given direction, either to advance or retard, by selectively blocking or permitting the flow of pressurized hydraulic fluid, preferably engine oil, from the recesses by controlling the position of a spool within a valve body of a control valve. The sprocket has a passage extending therethrough the passage extending parallel to and being spaced from a longitudinal axis of rotation of the camshaft. A pin is slidable within the passage and is resiliently urged by a spring to a position where a free end of the pin projects beyond the passage. The vane carries a plate with a pocket, which is aligned with the passage in a predetermined sprocket to camshaft orientation. The pocket receives hydraulic fluid, and when the fluid pressure is at its normal operating level, there will be sufficient pressure within the pocket to keep the free end of the pin from entering the pocket. At low levels of hydraulic pressure, however, the free end of the pin will enter the pocket and latch the camshaft and the sprocket together in a predetermined orientation.
In at least some of the about listed variable camshaft timing mechanisms, in order for a variable camshaft timing mechanism to operate with maximum efficiency it is typically desirable to limit the leakage of fluids from the device such as a phaser. In order to limit the leakage, elements such as sealing elements are used. The introduction of the elements or methods employed to limit the leakage of fluid also make it difficult to purge the air from the VCT device. Air inside the device is known to cause the VCT device to oscillate and cause impact at mechanical limits, which generates undesirable noise in the valve train.
Therefore, it is desirous to introduce a suitable venting means such as a vent passage into the VCT hydraulic chamber at predetermined time periods. The venting means would be connected to a lock pin mechanism as the venting outlet for allowing air within the chamber to escape in such a way that the vent would be open when the lock pin is engaged and closed when the lock pin is disengaged.
SUMMARY OF THE INVENTION
A vent passage is provided which leads into the VCT hydraulic chamber. This vent passage would be connected to the lock pin mechanism such that the vent would be open when the lock pin is engaged and closed when the lock pin is disengaged.
An open vent is provided which would allow air to escape from the VCT high-pressure chamber with the lock pin preventing the VCT from oscillating.
A closed vent is provided when the lock pin releases is in a releasing state, wherein the vent is closed, thereby preventing excess leakage from the VCT hydraulic chamber and thus limit the oscillation of the VCT caused by leakage.
Suitable dimensions or sizes of the vent passage are provided such that air would be allowed to escape the VCT working chamber before building sufficient oil pressure within the VCT device to release the lock pin. Thereby VCT operate quietly is assured in that the VCT device would not release the lock pin until sufficient air was purged. The result is that VCT device operates more quietly.
A phaser is provided such that air inside the phaser are released before mechanical movements between a rotor and a housing are allowed.
Accordingly, a VCT device including a housing and a rotor disposed to rotate relative to each other is provided. The housing has at least one cavity disposed to be divided by a vane rigidly attached to the rotor. The vane divides the cavity into a first chamber and a second chamber. The device further includes passages connecting the first and the second chamber facilitating the oscillation of the vane within the cavity by transferring fluid between the first chamber and the second chamber. The device includes: a locking member substantially disposed within a closure in the housing, the locking member locking the housing and the rotor free from relative rotation and independent of fluid flow; and at least one vent passage disposed between either the first or the second chamber and the closure in the housing; thereby air within the chamber is purged and noise stopped.
Accordingly, a method is provided in a VCT device including a housing and a rotor disposed to rotate relative to each other. The housing has at least one cavity disposed to be divided by a vane rigidly attached to the rotor. The vane divides the cavity into a first chamber and a second chamber. The device further includes passages connecting the first and the second chamber facilitating the oscillation of the vane within the cavity by transferring fluid between the first chamber and the second chamber. The method includes the steps of: providing a locking member substantially disposed within a closure in the housing, the locking member locking the housing and the rotor free from relative rotation and independent of fluid flow; and providing at least one vent passage disposed between either the first or the second chamber and the closure in the housing; thereby air within the chamber is purged and noise stopped.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a schematic of a phaser of the present invention.
FIG. 2 a shows a first aspect of the present invention.
FIG. 2 b shows a second aspect of the present invention.
FIG. 3 shows, in part, the VCT system of the present invention.
FIG. 4 shows a Cam Torque Actuated (CTA) VCT system applicable to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a vane-type VCT phaser comprises a housing ( 1 ), the outside of which has sprocket teeth ( 8 ) which mesh with and are driven by timing chain ( 9 ). Inside the housing ( 1 ), a cavity including fluid chambers ( 6 ) and ( 7 ) is defined. Coaxially within the housing ( 1 ), free to rotate relative to the housing, is a rotor ( 2 ) with vanes ( 5 ) which fit between the chambers ( 6 ) and ( 7 ), and a central control valve ( 4 ) which routes pressurized fluid via passages ( 12 ) and ( 13 ) to chambers ( 6 ) and ( 7 ), respectively. Pressurized fluid introduced by valve ( 4 ) into passages ( 12 ) will push vanes ( 5 ) counterclockwise relative to the housing ( 1 ), forcing fluid out of chambers ( 6 ) into passages ( 13 ) and into valve ( 4 ). A fluid passage ( 15 ) supplies fluid such as engine oil and suitably pressurizes a lock pin ( 10 ) slidably fitted within a casing ( 17 ). It will be recognized by one skilled in the art that this description is common to vane phasers in general, and the specific arrangement of vanes, chambers, passages and valves shown in FIG. 1 may be varied within the teachings of the invention. For example, the number of vanes and their location can be changed, some phasers have only a single vane, others as many as a dozen, and the vanes might be located on the housing and reciprocate within chambers on the rotor. The housing might be driven by a chain or belt or gears, and the sprocket teeth might be gear teeth or a toothed pulley for a belt.
Referring to FIG. 1 and the detail of FIG. 2 a , in the phaser of the invention, lock pin ( 10 ) slides along the walls of casing ( 17 ) which may be a bore in the housing ( 1 ), and is engaged by a spring ( 21 ) for allowing an inner end ( 20 ) of pin ( 10 ) to fit into a recess ( 19 ) formed in the rotor ( 2 ) to lock the rotor ( 2 ) and housing ( 1 ) into a fixed rotational position. Vent ( 11 ) allows any fluid which might leak past passage ( 15 ) before recess ( 19 ) is closed by an inner end ( 20 ) of lock pin ( 10 ) to be discharged.
The fluid passage ( 15 ) feeds pressurized fluid from the engine oil supply (not shown) into the recess ( 19 ). The dimensions of relevant parts such as passage ( 15 ) and lock pin ( 10 ) are chosen such that at engine start-up, the piston cannot push the lock pin ( 10 ) back against the force of the spring ( 21 ) until the supply oil pressure has risen to a level which is sufficient that fluid in passages ( 12 ) or ( 13 ) can fully fill chambers ( 6 ) and ( 7 ) and purge any air which might have been introduced due to leakage while the engine was shut down. In order to facilitate an improved means of purging the air inside the chambers ( 6 ) and ( 7 ), a vent passage ( 18 ) is provided which interposed between one of the chambers ( 6 ) and ( 7 ), and lock pin mechanism that has a suitable air outlet. For example, chamber ( 7 ) is connected via vent passage ( 18 ) to the lock pin mechanism as shown in FIG. 2 a , wherein vent ( 11 ) serves the dual purpose of both purging the air inside the chamber ( 7 ) and allowing any fluid which might leak past passage ( 15 ) to be discharged. In this case, lock pin ( 10 ) may have structure similar to a spool valve in that at a first position, air within chamber ( 7 ) is purged. Whereas, on the other hand, when the lock pin ( 10 ) is at a second position as shown in FIG. 2 b , vent passage ( 18 ) is structurally stopped from acting as a conduit for communicating between one chamber and the lock pin mechanism. The stoppage can be achieved in various ways. Depending on the shape of the lock pin, a flange can be formed around the same if the pin is of annular shape. If the lock pin body has an elongated polygonal shape, any element extending from the lock pin body that is sufficient to block vent passage ( 18 ) thereby stopping fluid communication function of the same is contemplated by the present invention. The flange or the element is denoted by numeral ( 23 ).
The present invention will be better understood by the following description. When fluid pressure has risen to a predetermined pressure ( 22 ) (or higher), lock pin ( 10 ) is pushed back from recess ( 19 ), as shown in FIG. 2 b . When the piston ( 10 ) is pushed out of the tapered recess ( 19 ), fluid can flow past the piston ( 10 ) and push against the larger area ( 20 ) of the lock pin ( 10 ). This larger area allows a lower pressure to hold the pin back than was required to move the piston away from the recess in the first instance. At this juncture, element ( 23 ) stops fluid communication via vent passage ( 18 ) between vent ( 11 ) and one of the chambers ( 6 ) and ( 7 ).
On the other hand, when pressure ( 22 ) is below the predetermined value, fluid communication via vent passage ( 18 ) between vent ( 11 ) and one of the chambers ( 6 ) and ( 7 ) resumes. For example, when the engine is shut down or the crank speed is below a predetermined limit, the pressure in passage ( 15 ) drops below the chosen pressure which will hold the pin ( 10 ) sufficiently against the force of the spring ( 21 ), and the lock pin ( 10 ) moves toward the rotor ( 2 ). When the pin ( 10 ) and recess ( 19 ) come into alignment, the pin ( 10 ) drops into the recess ( 19 ), and locks the rotor ( 2 ) and housing ( 1 ) once more.
FIG. 3 is a schematic depiction that shows, in part, the VCT system of the present invention. A null position is shown in FIG. 3 . Solenoid ( 320 ) engages spool valve ( 314 ) by exerting a first force upon the same on a first end ( 329 ). The first force is met by a force of equal strength exerted by spring ( 321 ) upon a second end ( 317 ) of spool valve ( 314 ) thereby maintaining the null position. The spool valve ( 314 ) includes a first block ( 319 ) and a second block ( 323 ) each of which blocks fluid flow respectively.
The phaser ( 342 ) includes a vane ( 358 ), a housing ( 357 ) using the vane ( 358 ) to delimit an advance chamber A and a retard chamber R therein. Typically, the housing and the vane ( 358 ) are coupled to crank shaft (not shown) and cam shaft (also not shown) respectively. Vane ( 358 ) is permitted to move relative to the phaser housing by adjusting the fluid quantity of advance and retard chambers A and R. If it is desirous to move vane ( 358 ) toward the retard side, solenoid ( 320 ) pushes spool valve ( 314 ) further right from the original null position such that liquid in chamber A drains out along duct ( 304 ) through duct ( 308 ). The fluid further flows or is in fluid communication with an outside sink (not shown) by means of having block ( 329 ) sliding further right to allow said fluid communication to occur. Simultaneously, fluid from a source passes through duct ( 313 ) and is in one-way fluid communication with duct ( 307 ) by means of one-way valve ( 315 ), thereby supplying fluid to chamber R via duct ( 305 ). This can occur because block ( 323 ) are moved further right causing the above one-way fluid communication to occur. When the desired vane position is reached, the spool valve is commanded to move back left to its null position, thereby maintaining a new phase relationship of the crank and cam shaft.
Referring to FIG. 4, a Cam Torque Actuated (CTA) VCT system applicable to the present invention is shown. The CTA system uses torque reversals in camshaft caused by the forces of opening and closing engine valves to move vane ( 442 ). The control valve in a CTA system allows fluid flow from advance chamber ( 492 ) to retard chamber ( 493 ) or vice versa, allowing vane ( 442 ) to move, or stops fluid flow, locking vane ( 442 ) in position. CTA phaser may also have oil input ( 413 ) to make up for losses due to leakage, but does not use engine oil pressure to move phaser.
The detailed operation of CTA phaser system is as follows. FIG. 4 depicts a null position in that ideally no fluid flow occurs because the spool valve ( 414 ) stops fluid circulation at both advance end ( 498 ) and retard end ( 410 ). When cam angular relationship is required to be changed, vane ( 442 ) necessarily needs to move. Solenoid ( 420 ), which engages spool valve ( 414 ), is commanded to move spool ( 414 ) away from the null position thereby causing fluid within the CTA circulation to flow. It is pointed out that the CTA circulation ideally uses only local fluid without any fluid coming from source ( 413 ). However, during normal operation, some fluid leakage occurs and the fluid deficit needs to be replenished by the source ( 413 ) via a one way valve ( 415 ). The fluid in this case may be engine oil. The source ( 413 ) may be the oil pan.
There are two scenarios for the CTA phaser system. First, there is the Advance scenario, wherein an Advance chamber ( 492 ) needs to be filled with more fluid than in the null position. In other words, the size or volume of chamber ( 492 ) is increased. The advance scenario is accomplished by way of the following.
Solenoid ( 420 ), preferably of the pulse width modulation (PWM) type, pushes the spool valve ( 414 ) toward right such that the left portion ( 419 ) of the spool valve ( 414 ) still stops fluid flow at the advance end ( 498 ). But simultaneously the right portion ( 422 ) moved further right leaving retard portion ( 410 ) in fluid communication with duct ( 499 ). Because of the inherent torque reversals in camshaft, drained fluid from the retard chamber ( 493 ) feeds the same into advance chamber ( 492 ) via one-way valve ( 496 ) and duct ( 494 ).
Similarly, for the second scenario which is the retard scenario wherein a Retard chamber ( 493 ) needs to be filled with more fluid than in the null position. In other words, the size or volume of chamber ( 493 ) is increased. The retard scenario is accomplished by way of the following.
Solenoid ( 420 ), preferably of the pulse width modulation (PWM) type, reduces its engaging force with the spool valve ( 414 ) such that an elastic member ( 421 ) or forces spool ( 414 ) to move lest. The right portion ( 422 ) of the spool valve ( 414 ) stops fluid flow at the retard end ( 410 ). But simultaneously the left portion ( 419 ) moves further right leaving Advance portion ( 498 ) in fluid communication with duct ( 499 ). Because of the inherent torque reversals in camshaft, drained fluid from the Advance chamber ( 492 ) feeds the same into Retard chamber ( 493 ) via one-way valve ( 497 ) and duct ( 495 ).
As can be appreciated, with the CTA cam phaser, the inherent cam torque energy is used as the motive force to re-circulate oil between the chambers ( 492 , 493 ) in the phaser. This varying cam torque arises from alternately compressing, then releasing, each valve spring, as the camshaft rotates. As can be appreciated, in order for a variable camshaft timing mechanism or device to operate with maximum efficiency, it is desirable to limit the leakage from the device. The same methods employed to limit the leakage of the oil also creates difficulties in purging the air from the VCT device. Air inside the device causes the VCT to oscillate and impact at its mechanical limits, which generates noise in the valve train.
It is contemplated that the present invention be applied to any hydraulically operated variable camshaft timing mechanism. The concept of the present invention is to introduce a vent passage into the VCT hydraulic chamber. This vent passage would be connected to the lock pin such that the vent would be open when the lock pin is engaged and closed when the lock pin is disengaged.
The open vent would allow air to escape from the VCT high-pressure chamber while the lock pin prevents the VCT from oscillating. When the lock pin is in a released state, it would close the vent and prevent excess leakage from the VCT hydraulic chamber and thus limit the oscillation of the VCT caused by leakage.
The vent passage could be sized such that air would be allowed to escape the VCT working chamber before building sufficient oil pressure in the VCT to release the lock pin. That would assure the VCT would not be released until sufficient air was purged to make the VCT operate quietly
The following are terms and concepts relating to the present invention.
It is noted the hydraulic fluid or fluid referred to supra are actuating fluids. Actuating fluid is the fluid which moves the vanes in a vane phaser. Typically the actuating fluid includes engine oil, but could be separate hydraulic fluid. The VCT system of the present invention may be a Cam Torque Actuated (CTA) VCT system in which a VCT system that uses torque reversals in camshaft caused by the forces of opening and closing engine valves to move the vane. The control valve in a CTA system allows fluid flow from advance chamber to retard chamber, allowing vane to move, or stops flow, locking vane in position. The CTA phaser may also have oil input to make up for losses due to leakage, but does not use engine oil pressure to move phaser. Vane is a radial element actuating fluid acts upon, housed in chamber. A vane phaser is a phaser which is actuated by vanes moving in chambers.
There may be one or more camshaft per engine. The camshaft may be driven by a belt or chain or gears or another camshaft. Lobes may exist on camshaft to push on valves. In a multiple camshaft engine, most often has one shaft for exhaust valves, one shaft for intake valves. A “V” type engine usually has two camshafts (one for each bank) or four (intake and exhaust for each bank).
Chamber is defined as a space within which vane rotates. Camber may be divided into advance chamber (makes valves open sooner relative to crankshaft) and retard chamber (makes valves open later relative to crankshaft). Check valve is defined as a valve which permits fluid flow in only one direction. A closed loop is defined as a control system which changes one characteristic in response to another, then checks to see if the change was made correctly and adjusts the action to achieve the desired result (e.g. moves a valve to change phaser position in response to a command from the ECU, then checks the actual phaser position and moves valve again to correct position). Control valve is a valve which controls flow of fluid to phaser. The control valve may exist within the phaser in CTA system. Control valve may be actuated by oil pressure or solenoid. Crankshaft takes power from pistons and drives transmission and camshaft. Spool valve is defined as the control valve of spool type. Typically the spool rides in bore, connects one passage to another. Most often the spool is most often located on center axis of rotor of a phaser.
Differential Pressure Control System (DPCS) is a system for moving a spool valve, which uses actuating fluid pressure on each end of the spool. One end of the spool is larger than the other, and fluid on that end is controlled (usually by a Pulse Width Modulated (PWM) valve on the oil pressure), full supply pressure is supplied to the other end of the spool (hence differential pressure). Valve Control Unit (VCU) is a control circuitry for controlling the VCT system. Typically the VCU acts in response to commands from ECU.
Driven shaft is any shaft which receives power (in VCT, most often camshaft). Driving shaft is any shaft which supplies power (in VCT, most often crankshaft, but could drive one camshaft from another camshaft). ECU is Engine Control Unit that is the car's computer. Engine Oil is the oil used to lubricate engine, pressure can be tapped to actuate phaser through control valve.
Housing is defined as the outer part of phaser with chambers. The outside of housing can be pulley (for timing belt), sprocket (for timing chain) or gear (for timing gear). Hydraulic fluid is any special kind of oil used in hydraulic cylinders, similar to brake fluid or power steering fluid. Hydraulic fluid is not necessarily the same as engine oil. Typically the present invention uses “actuating fluid”. Lock pin is disposed to lock a phaser in position. Usually lock pin is used when oil pressure is too low to hold phaser, as during engine start or shutdown.
Oil Pressure Actuated (OPA) VCT system uses a conventional phaser, where engine oil pressure is applied to one side of the vane or the other to move the vane.
Open loop is used in a control system which changes one characteristic in response to another (say, moves a valve in response to a command from the ECU) without feedback to confirm the action.
Phase is defined as the relative angular position of camshaft and crankshaft (or camshaft and another camshaft, if phaser is driven by another cam). A phaser is defined as the entire part which mounts to cam. The phaser is typically made up of rotor and housing and possibly spool valve and check valves. A piston phaser is a phaser actuated by pistons in cylinders of an internal combustion engine. Rotor is the inner part of the phaser, which is attached to a cam shaft.
Pulse-width Modulation (PWM) provides a varying force or pressure by changing the timing of on/off pulses of current or fluid pressure. Solenoid is an electrical actuator which uses electrical current flowing in coil to move a mechanical arm. Variable force solenoid (VFS) is a solenoid whose actuating force can be varied, usually by PWM of supply current. VFS is opposed to an on/off (all or nothing) solenoid.
Sprocket is a member used with chains such as engine timing chains. Timing is defined as the relationship between the time a piston reaches a defined position (usually top dead center (TDC)) and the time something else happens. For example, in VCT or VVT systems, timing usually relates to when a valve opens or closes. Ignition timing relates to when the spark plug fires.
Torsion Assist (TA) or Torque Assisted phaser is a variation on the OPA phaser, which adds a check valve in the oil supply line (i.e. a single check valve embodiment) or a check valve in the supply line to each chamber (i.e. two check valve embodiment). The check valve blocks oil pressure pulses due to torque reversals from propagating back into the oil system, and stop the vane from moving backward due to torque reversals. In the TA system, motion of the vane due to forward torque effects is permitted; hence the expression “torsion assist” is used. Graph of vane movement is step function.
VCT system includes a phaser, control valve(s), control valve actuator(s) and control circuitry. Variable Cam Timing (VCT) is a process, not a thing, that refers to controlling and/or varying the angular relationship (phase) between one or more camshafts, which drive the engine's intake and/or exhaust valves. The angular relationship also includes phase relationship between cam and the crankshafts, in which the crank shaft is connected to the pistons.
Variable Valve Timing (VVT) is any process which changes the valve timing. VVT could be associated with VCT, or could be achieved by varying the shape of the cam or the relationship of cam lobes to cam or valve actuators to cam or valves, or-by individually controlling the valves themselves using electrical or hydraulic actuators. In other words, all VCT is VVT, but not all VVT is VCT.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | A device includes: a locking member substantially disposed within a closure in the housing, the locking member locking the housing and the rotor free from relative rotation and independent of fluid flow; and at least one vent passage disposed between either the first or the second chamber and the closure in the housing; thereby air within the chamber is purged and noise stopped. | 5 |
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to a metal oxide semiconductor field effect transistor (MOSFET) power device, especially to a MOSFET power device with multi gates connection.
[0003] Description of Prior Art
[0004] Metal oxide semiconductor field effect transistor (MOSFET) power device is a field effect transistor with extensive applications in analog and digital circuits and is a main stream device for power device in power electronic usage. The MOSFET power device has low power dissipation due to very low conduction resistance and high input impedance. In comparison with power bipolar transistor, the MOSFET power device further has the advantage of high switching speed for its single carrier nature (no minority carrier). For now, MOSFET power devices are popular for high frequency and low voltage applications.
[0005] To further increase device density and reduce on resistance for device, MOSFET power devices with trench gate structure are important issues. However, the gate-drain charge (Qgd) increases as the device density increases; therefore and the charging-discharging speed of gate is affected. Even though split gate structure is developed to reduce gate-drain area and reduce gate-drain capacitance. The gate-drain capacitance of the MOSFET power devices still needs improvements.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a metal oxide semiconductor field effect transistor (MOSFET) power device with reduced capacitance.
[0007] Accordingly, the present invention provides a metal oxide semiconductor field effect transistor (MOSFET) power device with multi gates connection, comprising: a first-conductive type substrate; a first-conductive type epitaxial layer arranged on the first-conductive type substrate; and a plurality of device trenches defined on an upper face of the first-conductive type epitaxial layer, each of the device trenches having, from bottom of the trench to top of the trench, a bottom gate, a split gate and a trench gate, wherein a bottom insulating layer is formed between the bottom gate and the first-conductive type epitaxial layer, an intermediate insulating layer is formed between the bottom gate and the split gate, and an upper insulating layer is formed between the split gate and the trench gate.
[0008] Accordingly, the present invention provides a method for manufacturing metal oxide semiconductor field effect transistor (MOSFET) power device with multi gates connection, comprising: providing a first-conductive type substrate and a first-conductive type epitaxial layer arranged on the first-conductive type substrate; defining a plurality of device trenches defined on an upper face of the first-conductive type epitaxial layer, each of the device trenches having, from bottom of the trench to top of the trench, a bottom gate, a split gate and a trench gate, wherein a bottom insulating layer is formed between the bottom gate and the first-conductive type epitaxial layer, an intermediate insulating layer is formed between the bottom gate and the split gate, and an upper insulating layer is formed between the split gate and the trench gate.
[0009] The gate-source area of the MOSFET power device with multi gates connection according to the present invention can be reduced because the bottom gate is electrically isolated with other elements. The capacitance and the resistance of the MOSFET power device can be reduced to enhance operation bandwidth.
BRIEF DESCRIPTION OF DRAWING
[0010] One or more embodiments of the present disclosure are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements. These drawings are not necessarily drawn to scale.
[0011] FIGS. 1 to 9 show the sectional views for illustrating the manufacture process for the metal oxide semiconductor field effect transistor (MOSFET) power device with multi gates connection of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] As shown in FIG. 1 , a substrate structure is provided, which includes a heavily-doped N type silicon substrate 101 (N+ silicon substrate) and a lightly-doped doped N type silicon epitaxial layer 102 (N− silicon epitaxial layer). In the shown embodiment, the lightly-doped doped N type silicon epitaxial layer 102 is drawn to be thicker than the heavily-doped N type silicon substrate 101 . However, in practical device, the lightly-doped doped N type silicon epitaxial layer 102 can be thinner than the heavily-doped N type silicon substrate 101 and the scope of the present invention is not limited by the shown embodiment. A plurality of photoresist patterns (not shown) are formed by using photolithography process and the photoresist patterns are used as etching masks to define a plurality of device trenches 200 and at least one termination trench 300 on the lightly-doped doped N type silicon epitaxial layer 102 . The device trenches 200 on the left side of the dashed line in FIG. 1 are corresponding to the device region of the MOSFET power device and the termination trench 300 on the right side of the dashed line in FIG. 1 are corresponding to the termination region of the MOSFET power device. After the formation of the trenches 200 , 300 , an optional sacrificial oxidation can be performed, namely by forming a thin oxide layer and then performing an oxide etching step, the damaged surface of the trenches 200 , 300 can be removed to make the sidewall of trenches 200 , 300 become smooth. As also shown in FIG. 1 , a thermal oxidation process is performed for the lightly-doped doped N type silicon epitaxial layer 102 formed with the trenches 200 , 300 to form an oxide layer 30 , which is arranged on inner wall of the trenches 200 , 300 and the exposed surface of the lightly-doped doped N type silicon epitaxial layer 102 . The thickness of the oxide layer 30 is, for example, 3000-6000 angstrom (Å). Moreover, the oxide layer 30 can also be formed by deposition instead of thermal oxidation.
[0013] As shown in FIG. 2 , a polysilicon layer 20 A is formed atop the oxide layer 30 to fill the trenches 200 , 300 and cover the lightly-doped doped N type silicon epitaxial layer 102 . The thickness of the polysilicon layer 20 A, counted from an upper face of the oxide layer 30 on the lightly-doped doped N type silicon epitaxial layer 102 , is for example 1.5-2.5 um.
[0014] As shown in FIG. 3 , after forming the polysilicon layer 20 A, an etching back process (such as a dry etching process) is performed to remove part of the polysilicon layer 20 A until no polysilicon layer 20 A is present in termination trench 300 and part of polysilicon layer 20 A is present in device trenches 200 . As also shown in FIG. 3 , after the etching back process, part of polysilicon layer 20 A remains in device trench 200 , which will be used as a bottom gate 20 in the MOSFET power device of the present invention. Moreover, the part of the oxide layer 30 between the bottom gate 20 and the N type silicon epitaxial layer 102 is a bottom insulating layer 32 .
[0015] As shown in FIG. 4 , an oxidation process, such as Tetraethyl Orthosilicate (LPTEOS) process or CVD process, is further conducted to form a deposited oxide layer 22 A, which is formed atop the bottom gate 20 and fills the trenches 200 , 300 as well as is formed atop the oxide layer 30 on the N type silicon epitaxial layer 102 . The thickness of the deposited oxide layer 22 A, counted from an upper face of the oxide layer 30 on the lightly-doped doped N type silicon epitaxial layer 102 , is for example 1000-3000 angstrom. Moreover, as shown in FIG. 5 , a CMP process is conducted to remove the part of the deposited oxide layer 22 A and the part of the oxide layer 30 on the upper face of the N type silicon epitaxial layer 102 such that the followed etching step for the oxide layer can be better controlled.
[0016] As shown in FIG. 6 , a dry etching step is then performed to remove the part of the deposited oxide layer 22 A in the trenches 200 , 300 until a layer of oxide remains atop the bottom gate 20 , which functions as an intermediate insulating layer 34 between the bottom gate 20 and a split gate (not shown) to be formed.
[0017] As shown in FIG. 7 , steps similar to those shown in FIGS. 2-6 are performed. Namely, a polysilicon layer with thickness of 2-3 um is grown and etched back until the polysilicon layer only remains in the device trenches 200 . As also shown in FIG. 7 , a polysilicon layer remains atop the intermediate insulating layer 34 in the device trench 200 , which will function as split gate 22 . Afterward, an oxidation process, such as Tetraethyl Orthosilicate (LPTEOS) process or CVD process, is further conducted to form a deposited oxide layer (not labeled). Moreover, a CMP process is conducted to remove the part of the deposited oxide layer on the upper face of the N type silicon epitaxial layer 102 , and a dry etching step is performed to remove the part of the deposited oxide layer in the trenches 200 , 300 until a layer of oxide remains atop the split gate 22 , which functions as an upper insulating layer 36 between the split gate 22 and a trench gate (not shown) to be formed.
[0018] As shown in FIG. 8 , a polysilicon layer with thickness of 2-3 um is grown and etched back until the polysilicon layer only remains in the device trenches 200 . In FIG. 8 , a remained polysilicon layer functioning as trench gate 24 is placed atop the upper insulating layer 36 . Afterward, an etching back step for oxide is performed.
[0019] As shown in FIG. 9 , after forming the trench gate 24 , ion implantation and driving-in processes are performed to form P body area 40 and N type source regions 42 , which are near the upper face of the N type silicon epitaxial layer 102 and outside the device trench 200 . Afterward, interlayer dielectric (ILD) layer 44 is formed atop the resulting structure and then photolithography process is performed on the ILD layer to define source trench 400 . Contact metal layer 46 is then formed atop the source trench 400 , and the contact metal layer 46 can be Ti or TiN layer such that silicide can be formed between a later-formed metal electrode and the underlying silicon layer to reduce electrical resistance. After forming the metal contact layer 46 , a metal electrode layer 48 and a passivation layer (not shown) are respectively formed.
[0020] With reference again to FIG. 9 , this figure also shows a sectional view of the MOSFET power device with multi gates connection of the present invention. The MOSFET power device comprises an N type substrate structure 100 (including a heavily-doped N type silicon substrate 101 and a lightly-doped doped N type silicon epitaxial layer 102 ), a plurality of device trenches 200 in the device region, and at least one termination trench 300 in the termination region. Moreover, the MOSFET power device further comprises, in each device trench 200 and from the bottom to the top of the trench, a bottom gate 20 , a split gate 22 and a trench gate 24 , where a bottom insulating layer 32 is placed between the bottom gate 20 and the lightly-doped doped N type silicon epitaxial layer 102 , an intermediate insulating layer 34 is placed between the bottom gate 20 and the split gate 22 , and an upper insulating layer 36 is placed between the split gate 22 and the trench gate 24 . Moreover, the MOSFET power device further comprises a P body area 40 and N type source regions 42 , which are near the upper face of the N type silicon epitaxial layer 102 and outside the device trench 200 . The N type source regions 42 are placed within the P body area 40 . Moreover, the MOSFET power device further comprises gate oxide layer 38 between the trench gate 24 in the device trench 200 and the N type source region 42 outside the device trench 200 . Moreover, the MOSFET power device further comprises source trenches 400 , each between the adjacent device trenches 200 and ILD layer 44 beside the source trench 400 and atop the trench gate 24 and the N type source regions 42 . The MOSFET power device further comprises a metal contact layer 46 on inner wall of the source trench 400 and atop the ILD layer 44 , and comprises a metal electrode layer 48 atop the metal contact layer 46 to function as source electrode.
[0021] In the MOSFET power device shown in FIG. 9 , the trench gate 24 electrically connects with gate electrode (not shown) to obtain operation voltage, and the split gate 22 electrically connects with the N type source regions 42 through buried-in electrode (not shown). Moreover, the bottom gate 20 is electrically isolated with the split gate 22 through the intermediate insulating layer 34 therebetween and is not electrically connected with other elements of the MOSFET power device. By the provision of the bottom gate 20 , the gate-drain area can be further reduced such that the equivalent capacitance and equivalent resistance of the MOSFET power device can be further reduced to enhance the operation bandwidth.
[0022] The person skilled in the art can know other implementations are also feasible for above-mentioned embodiment. For example, the N type substrate structure 100 can be replaced with P type substrate structure, and correspondingly the N type source regions 42 are replaced with P type source regions, and the P body area 40 is replaced with N body area.
[0023] Thus, particular embodiments have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in the claims may be performed in a different order and still achieve desirable results. | A metal oxide semiconductor field effect transistor (MOSFET) power device with multi gates connection includes a first-conductive type substrate, a first-conductive type epitaxial layer arranged on the first-conductive type substrate, a plurality of device trenches defined on an upper face of the first-conductive type epitaxial layer. Each of the device trenches has, from bottom of the trench to top of the trench, a bottom gate, a split gate and a trench gate. A bottom insulating layer is formed between the bottom gate and the bottom of the trench, an intermediate insulating layer is formed between the bottom gate and the split gate, an upper insulating layer is formed between the split gate and the trench gate. | 7 |
BACKGROUND OF THE INVENTION
The present invention generally relates to a method and device for flowing a liquid on a surface.
There are many applications in which it is desirable to flow a liquid on a surface. An example of such an application is in patterning or other processing of surfaces. Patterning and processing of surfaces with liquids is becoming increasingly important in a range of fields, including chemistry, biology, biotechnology, materials science, electronics, and optics. Patterning a surface by applying a liquid to the surface typically involves confinement of the liquid to defined regions of the surface.
A surface is typically wettable by a liquid if the contact angle between a drop of the liquid and the surface is less than 90 degrees. A channel for carrying a liquid is typically wettable if the channel exerts a negative pressure on the liquid when partially filled. Such a negative pressure promotes filling of the channel by the liquid. In a channel having a homogeneous surface, a negative pressure arises if the contact angle between the liquid and the surface is less than 90 degrees. A surface is typically regarded as more wettable if the contact angle between the surface and the liquid is smaller and less wettable if the contact angle between the surface and the liquid is higher.
One conventional surface patterning technique is lithography. In lithography, a mask is usually applied to the surface to be patterned. Apertures are formed in the mask to define regions of the surface to be exposed for treatment. Those areas of the surface remaining covered by the mask are protected from treatment. The mask is typically formed from a patterned layer of resist material. The surface carrying the mask is then typically immersed in a bath of chemical agents for treating the exposed regions of the surface. Lithography is a relatively expensive process to perform, involving multiple steps. With the possible exception of in situ synthesis of short DNA strands, lithography is generally unsuitable for handling and patterning biomolecules on surfaces. Lithography is also unsuitable for simultaneously processing surfaces with different chemicals in parallel, as described by Whitesides, Annu. Rev. Biomed. 3 (2001), 335-373.
There can be incompatibility between different process steps or chemicals used in lithography and between various surface layers processed by lithography.
Another conventional surface patterning technique is drop delivery. Drop delivery systems, such as pin spotting systems, ink jet systems, and the like, typically project a relatively small volume of liquid onto a specific location on a surface. See Shena, M., “ Microarray biochip technology ”, Eaton Publishing 2000. However, these systems have limited resolution due to spreading of dispensed drops on the surface. Additionally, the quality of patterns formed by such systems is strongly limited by drying of the delivered liquid, as described by Smith, J. T., “ Spreading Diagrams for the Optimization of Quill Pin Printed Microarray Density”, Langmuir, 18 (2002), p 6289-6293.
These systems are not generally useful for dissolving or extracting materials from a surface. Additionally, these systems do not facilitate a flow of liquid over a surface. Furthermore, these systems are not suited to process a surface sequentially with several liquids.
PCT WO 01/63241 A2 describes a surface patterning technique involving a device having a channel with a discharge aperture. A matching pillar is engaged with the discharge aperture to promote deposition of molecules on the top surface of the pillar. A disadvantage with this device is that it is not possible to vary patterning conditions for different pillars individually. Another disadvantage is that it is not capable of establishing a flow on a surface. Exposure of the surface to the liquid needs to be sufficiently long to allow reagents to reach the surface by diffusion. The method also requires a surface with pillars matching the aperture. Fabrication of such a surface requires expensive clean-room equipment and etching tools. This can increase cost per patterned surface. Precise alignment of the device with the pillars before engagement is required. Additionally, the pillars need pretreatment to ensure the confinement of the liquid. Spacing between the discharge aperture and the pillars needs external control.
Yet another conventional surface patterning technique involves application of a microfluidic device to the surface. An example of such a device is described in U.S. Pat. No. 6,089,853. The device described therein can establish a flow of liquid over a surface. The flow can be created via capillary action in the device. The device can treat a surface with multiple different liquids in parallel. However, the device must be sealed to the surface in the interests of confining the liquid to the region of the surface to be treated. Such confinement allows the formation of patterns with relatively high contrast and resolutions. These are desirable qualities where biomolecules are patterned on a surface for biological screening and diagnostic purposes.
In addition, the device must be placed on the surface to be treated and sealed around the processing regions before it can be filled with treatment liquid. If the flow is created by capillary action, other problems arise. For example, service ports in the device must be filled with treatment liquid for each patterning operation. In addition, only one liquid can be delivered to each channel in the device. The liquid cannot be flushed out of the or each channel before separation of the device from the surface. Furthermore, the treatment liquid tends to spread away from the regions of the surface to be treated during removal of the device from the surface.
Also, the device is not suitable for processing a surface sequentially with several liquids. If the flow is created by external actuation, such as pressurization, electric fields, or the like, then other problems arise. For example, an individual connection from the actuator must be made to each channel in the device. Such connections to peripheral equipment limit the density of channels that can be integrated into the device and individually addressed. Pumping, valving, and control complexity increases as the number of channels increases. External connections create dead volume between the device and external actuators because of the intervening conduits.
Another microfluidic device for localized processing of a surface is described in IBM Technical Disclosure Bulletin reference RD n 446 Article 165 Page 1046. This device is similar to that described in U.S. Pat. No. 6,09,853. The device permits several liquids to be flushed in sequence over the same surface area without requiring separation of the device from the surface. Such a device is thus useful for chemical and biological reactions involving the sequential delivery of several liquids. A disadvantage associated with this device however is that it must be sealed around the region of the surface to be treated before filling. Another disadvantage is that the liquids cannot be filled prior to application on the device to the surface. Each additional step requires supplementary filling of the relevant liquid. Another disadvantage is that the device cannot be removed from the surface while the service ports contain liquid without liquid spreading over the surface beyond the region to be exposed.
Another conventional device for confining liquids to a predefined pattern between a top and bottom surface without involving a seal is described in European Patent 0 075 605. This device is useful for performing optical analysis of a liquid trapped between the top and bottom surface. However, the device requires predefined topographical or chemical patterns on both the top and bottom surfaces. Also, the device, having no inlet or outlet ports, is not suitable for the transport of liquids.
Another device for guiding liquids along a predetermined path is described in WO 99/56878. This device can flow several liquids simultaneously over a surface without involving seal to confine the liquids. However, a disadvantage of this device is that separation gaps between paths have to be capillary inactive. This limits path sizes to greater than 1 mm. Otherwise meniscus pressures produce uncontrolled spreading of liquid. Another disadvantage of this device is that liquid is not retained after separation and can instead spread over the surface. A further disadvantage of this device is that liquid delivery requires an external connection to each path. Cumbersome peripheral flow control devices are also required.
Yet another method for guiding liquid along a surface without involving a seal is described in Zhao et al., Science, Vol. 291 (2001), p. 1023-1026. Here, the surface is patterned with a wettability pattern. Specifically, two wettable paths mirroring each other are defined on otherwise non-wettable top and bottom surfaces. This produces “virtual” channels without lateral walls that can have micrometer width. A disadvantage of this method is that it requires wettability patterns on both the top and bottom surfaces. Additionally, the wettability contrast between the two patterns needs to be very high, and requires both non-wettable areas on the top and bottom surfaces and highly wettable areas within the virtual channel. Furthermore, the two patterns have to match each other exactly in shape and alignment. Capillary action can used to fill the channels, but the liquid cannot be removed or exchanged. This method is also susceptible to uncontrolled spreading of liquid because it is relatively difficult to produce sufficiently non-wettable surfaces. A external pump may be used to deliver the liquid, but if the pump pressure exceeds a relatively low level, liquid will overflow the defined flow path. Furthermore, external pumping requires external connections to each flow path, thus limiting integration. As indicated earlier, external connections create dead volume in pump connecting conduits.
It would be desirable to provide a technique for flowing a liquid over a surface in a more versatile and convenient manner.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, there is now provided a device for flowing a liquid on a surface, the device comprising: a flow path; a first port for supplying the liquid to one end of the flow path and for applying a first port pressure for retaining the liquid when the flow path is remote from the surface; a second port for receiving the liquid from the other end of the flow path and for applying a second port pressure such that the difference between the first and second negative port pressures is oriented to promote flow of the liquid from the first port to the second port via the flow path in response to the flow path being located proximal to the surface and the liquid in the device contacting the surface; and, the first and second port pressures being such that the liquid is drawn towards at least the second port in response to withdrawal of the flow path from the surface.
The devices preferably comprises a protrusion extending into the flow path adjacent the first port for directing the liquid from the first port towards the surface. The protrusion may be formed from a resilient material to prevent damage to the device and/or surface. The device may comprise a peripheral flange surrounding the flow path for sealing the flow path to the surface when the device is proximal to the surface. In a preferred embodiment of the present invention, the device comprises: a first opening communicating between the first port and the flow path for applying a first opening pressure to the liquid in the first port, the first opening pressure being more negative than the first port pressure; and, a second opening communicating between the flow path and the second port for applying a second opening pressure to the liquid in the flow path, the second opening pressure being more negative than the first port pressure.
The device preferably, comprises sides less wettable by the liquid and sides more wettable by the liquid, wherein the flow path is located on a more wettable side surrounded by less wettable sides. In a particularly preferred embodiment of the present invention, the device comprises a body housing the first port and the second port and an extension protruding from the body to form the flow path, the first and second openings being disposed at opposite ends of the extension. Sides of the extension surrounding the flow path are preferably less wettable to the liquid than the flow path. The flow path is thus defined by and located at the extremity of the extension. A surface placed proximal and facing the extremity can form surface channel within the intervening gap. Liquid can be confined and guided within such a surface channel via interfacial tension without a physical seal. This effectively prevents trapping of bubble in the flow path. Entrapment of bubbles can adversely affect the flow rate of liquid. The flow path may be straight or curved.
The first port may comprise a first capillary network for applying the first port pressure. The first capillary network may comprise at least one of a plurality of parallel capillary members, a mesh, a porous material, and a fibrous material. The second port may comprise a second capillary network for applying the second port pressure. The second capillary network may comprise at least one of a plurality of parallel capillary members, a mesh, a porous material, and a fibrous material. The device may comprise a plurality of first ports each coupled to the flow path. Similarly, the device may comprise a plurality of second ports each coupled to the flow path. The flow path may have a curved cross section.
Alternatively, the flow path may have a rectangular cross section. Devices embodying the present invention may be of unitary construction and may be formed from any one of elastomer, silicon, SU-8, photoresist, thermoplastic, ceramic, and metal. Alternatively, devices embodying the present invention may be of layered construction, wherein each layer is formed from one of elastomer, silicon, SU-8, photoresist, thermoplastic, metal, and ceramic. In a particularly preferred embodiment of the present invention, the flow path is approximately 100 micrometers in length and approximately 100 micrometers in width, the volumes of first and second ports are 500 nanoliters each, and, in use, the protrusion defines a spacing between the device and the surface in region of between 5 and 10 micrometers. The first and second port pressures may be such that the liquid is drawn towards the first port and the second port in response to withdrawal of the flow path from the surface. The present invention also extends to an array of applicator devices each as herein before described.
Viewing the present invention from another aspect, there is now provided a method for flowing a liquid on a surface, the method comprising: supplying the liquid from a first port of an applicator device to one end of a flow path of the device; applying to the liquid a first port pressure via the first port; receiving the liquid from the other end of the flow path in a second port of the device; applying to the liquid via the second port a second port pressure different to the first port pressure; promoting, via the difference between the first and second port pressures, flow of the liquid from the first port to the second port via the flow path in response to the flow path being located proximal to the surface and the liquid therein contacting the surface; and, drawing, via the first and second port pressures, the liquid towards at least the second port in response to withdrawal of the flow path from the surface.
The method may comprise, following withdrawal of the flow path from the surface, relocating the device at another position on the surface. Equally, the method may comprise, following withdrawal of the flow path from the surface, relocating the device on another surface. In a preferred embodiment of the present invention, the method comprises contacting the surface with the device and thereafter spacing the device from the surface to define a surface channel between the surface and the flow path for passage of the liquid from the first port to the second port. The method may comprise locating the device in a humid environment to initialize the flow of the liquid from the first port to the second port. The method may also comprise cooling the surface and/or the device to initialize the flow of the liquid via condensation. Alternatively, the method may comprise applying an electric field between the device and the surface to initialize the flow of the liquid from the first port to the second port. Equally, the method may comprise applying a pressure pulse to the liquid to initialize the flow of the liquid from the first port to the second port. Alternatively, the method may comprise applying a heat pulse to the liquid to initialize the flow of the liquid from the first port to the second port via vaporization of the liquid.
In a preferred embodiment of the present invention, the method comprises reversing the direction of flow of the liquid by reversing the pressure difference between the first port and the second port. The method may also comprise drawing, via the first and second port pressures, the liquid towards the first and second ports in response to withdrawal of the flow path from the surface.
In a particularly preferred embodiment of the present invention, there is now provided a device for flowing a liquid over a surface. The device comprises: a flow path; a first port for supplying the liquid to the flow path; a first opening communicating between the first port and one end of the flow path; a second port for receiving the liquid from the flow path; and, a second opening communicating between the other end of the flow path and the second port. In operation, engagement of the device with a surface initiates flow of the liquid from the first port to the second port via the flow path. The flow of liquid is curtailed by disengaging the device from the surface. Thus, the flow of liquid from the first port to the second port can be started and stopped by engaging and disengaging the device with the surface. The flow path acts as an operational fluidic channel when the device is engaged with the surface. This technology is hereinafter referred to as Surface Assisted Liquid Transfer technology or SALT technology. Accordingly, devices and modules based on this technology may be hereinafter referred to as SALT devices. The operational fluidic channel created by engaging the device with the surface will hereinafter be referred to as a surface channel.
In SALT devices embodying the present invention, pressures in the first and second ports need not be varied during operation of the device. This is because engagement of the device with the surface creates a condition in which liquid automatically flows between the first and second ports. This condition can be freely disrupted by disengaging the device from the surface, again without requiring further control of the pressure in either of the first and second ports.
The surface channel initially provides capillary action that transports the liquid from the first opening to the second opening. Thereafter, a pressure difference between first and second ports generates a flow of liquid from the first port to the second port. This effect is suppressed when the device is disengaged from the surface. Thus, the flow of liquid between first and second ports is curtailed. In a preferred embodiment of the present invention, the first port applies a negative pressure, P 1 <0, to the liquid. Similarly, the second port applies a negative pressure to the liquid, P 2 <0, P 2 <P 1 . The pressure is thus such that the liquid flows from the first port to the second port when the surface channel is active. In a particularly preferred embodiment of the present invention, P 1 and P 2 are generated by capillary active structures or “capillary pumps”. The capillary pumps may comprise capillary networks as herein before described. The volumes of the first and second ports may be commensurate.
An advantage associated with SALT devices is that they can be pre-filled with processing liquids for subsequent repetitive application and removal from areas of surfaces to be processed. Surface processing can be repeated multiple times from the same SALT device without refilling and thus delay. Another advantage associated with SALT devices is that they can deliver a series of different liquids and control the flow of each more easily than in conventional delivery techniques. Yet another advantage associated with SALT devices is that they can be swiftly mass produced via conventional microfabrication techniques. A further advantage of SALT devices is that they can include shallow conduits in processing areas to speed up mass-transport limited chemical reactions. An additional advantage of SALT devices is that they can employ minute amounts of processing reagents without depletion because the flow can be interactively controlled to renew the reagents as necessary.
In typical applications, a SALT device can be placed at an arbitrary location on a surface and process parameters can be controlled via channel dimensions and contact time. Arrays of SALT devices are relatively easy to fabricate. In preferred embodiments of the present invention, flow control is integrated into each SALT device. Such arrays can comprise multiple independent fluidic zones to facilitate parallel processing of multiple areas of a surface with different liquids.
SALT devices may be employed in many applications. For example, SALT devices can be employed to deposit biomolecules in selected regions of a surface to make bio-arrays, thus facilitating mass fabrication of bio-chips. SALT devices can be equally employed in subjecting selected areas of a surface to other processes, such as processes for: repairing pattern defects on a surface; etching specific areas of a surface; depositing metal on a surface; localizing an electrochemical reactions on a surface; depositing catalytic particles for electroless deposition of metals, deposition glass or latex beads or other particles on a surface; passivating specific areas of a surface; patterning proteins, DNA, cells, or other biological entities on a surface; making assays; staining cells; collecting cells, proteins, or other particles from a surface; retrieving analytes or specifically bound biomolecules from arrays on a surface; extracting DNA, proteins, or other molecules from gels; and, coupling collected cells or molecules to an analysis system.
Examples of such an analysis system include liquid chromatography or electrophoresis systems. Devices embodying the present invention may be employed to flow the products of such an analysis system one or more areas of a surface. In other applications, the surface and/or the device may be transparent to permit optical monitoring of the flow and/or optical detection of molecules. In further applications, the surface may contain sensing systems, such as electrodes, membranes, wave guides, and associated transducers to permit detection of molecules in the liquid flowing over the surface. Other processes benefiting from SALT technology will be apparent. SALT devices can also be employed in the delivery of small volumes of samples to test regions formed in a surface. It will thus be appreciated that SALT technology may be employed in the detection of diseases and/or pollutants through the processing of specific areas of a surface.
In accordance with another aspect of the present invention, there is now provided a device for applying a liquid to a surface, the device comprising a well for carrying the liquid, an opening in the well for communicating liquid from the well to the surface via a conduit having outer sides of limited wettability to the liquid.
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 cross sectional side view of a SALT applicator device embodying the present invention carrying a liquid;
FIG. 2 is a cross sectional side view of the device in contact with a surface with flow of the liquid initiated;
FIG. 3 is a cross sectional side view of the device during flow of the liquid;
FIG. 4 is a cross sectional end view of the device during flow of the liquid
FIG. 5 is a cross sectional side view of the device on removal from the surface;
FIG. 6 is a cross sectional end view of an example of a first port for a SALT device embodying the present invention;
FIG. 7 is a plan view of another example of a SALT device embodying the present invention;
FIG. 8 is a cross sectional end view of a flow path for a SALT device embodying the present invention;
FIG. 9 is a cross sectional end view of a flow path for a another SALT device embodying the present invention;
FIG. 10 is a cross sectional side view of another SALT device embodying the present invention;
FIG. 11 , is a cross sectional side view of a SALT device embodying the present invention used in combination with a patterned surface;
FIG. 12 , is a cross sectional end view of the device used in combination with the patterned surface;
FIG. 13 is a cross sectional side view of yet another SALT device embodying the present invention;
FIG. 14 is a cross sectional side view of the device shown in FIG. 13 in operation;
FIG. 15 is a cross sectional end view of the device shown in FIG. 13 in operation;
FIG. 16 is a cross sectional side view of a further SALT device embodying the present invention;
FIG. 17 is a cross sectional side view of a SALT array embodying the present invention;
FIG. 18 is a cross sectional end view of the SALT array; and,
FIG. 19 is a cross section side view of an interconnected SALT array embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , an example of a SALT applicator device embodying the present invention comprises a body 10 formed from a material such as PDMS, silicon, SU-8, photoresist, plastics, and metals. A first port 20 and a second port 30 are formed on one side of the body 10 . On the other side of the body 10 is narrow extension. A flow path 40 is defined is defined by the base 130 of the extension. The flow path may be straight or curved. A first opening 50 communicates between the first port 20 and one end of the flow path 40 . Similarly, a second opening 60 communicates between the second port 30 and the other end of the flow path 40 . The flow path 40 thus extends between the first port 20 and the second port 30 . In operation, the first port 20 acts as a fill port and the second port 30 acts as a flow promotion port. The liquid 70 is initially introduced to the first port 20 .
The first port 20 holds the liquid 70 at pressure P 1 . P 1 is preferably negative. P 1 <0. This contributes to retaining the liquid 70 in the first port 20 . The first opening 50 is wettable to the liquid and provides a capillary or meniscus pressure. This pressure exerts a negative first opening pressure OP 1 <0 on the liquid 70 in the first port 20 . OP 1 <P 1 . Therefore, OP 1 sucks the liquid from the first port 20 into the first opening 50 towards the flow path 40 . The first opening 50 widens at its intersection with the flow path 40 . The capillary pressure provided by the first opening 50 is therefore suppressed at this point. A protrusion 90 extends out of the body 10 into the flow path 40 adjacent the first opening 50 . The protrusion 90 is wettable by the liquid 70 . In operation, the protrusion sucks up the liquid 70 to its tip by capillary force. The protrusion may be resilient to prevent damage to the device or the surface 80 . In other embodiments of the present invention, there may be multiple protrusions 90 spaced along the flow path 40 to ensure that the surface channel 100 has uniform depth along its length.
In some cases P 1 may vary and may be greater than or equal to 0. This can arise, for example, when the first port 20 is overfilled with the liquid 70 . This leads to the liquid 70 having a convex surface. Such a surface is a source of positive pressure albeit of relatively low magnitude. In such a case, the opening 50 is filled with the liquid 70 up to the intersection with the flow path 40 and the protrusion 90 . Relatively small dimensions of both the opening 50 and the protrusion 90 are desirable for forming relatively high curvatures in the surface of the liquid 70 . By virtue of tension between the liquid and the surrounding medium, such curvatures produce relatively high pressures that confine the liquid 70 within the first port 20 and the opening 50 despite a positive pressure head.
Initiation of flow from the first port 20 to the second port 30 will now be described with reference to FIG. 2 . Engagement of the device with the surface 80 creates a surface channel 100 corresponding to the flow path 40 . The protrusion 90 abuts the surface 80 to define the size of the surface channel 100 , together with the flow path 40 . The surface channel 100 provides a capillary pressure, CP, that propels the liquid 70 from the first opening 50 to the second opening 60 . CP<P 2 and CP<0. The magnitude of CP is determined by the surface tension of the liquid 70 , the contact angles of the liquid 70 with the flow path 40 and the surface 80 , and the size of the gap formed between the flow path 40 and the surface 80 . It is thus possible to tune CP by varying the size of the gap between the surface 80 and the device. The smaller the gap, the higher the magnitude of CP. The larger the gap, the smaller the magnitude of CP.
The surface 80 need not be completely flat, but can be rough, corrugated, porous, fibrous, and/or chemically inhomogeneous. It should also be appreciated that the flow path 40 can be filled with the liquid 70 even if the device is slightly tilted relative to the surface 80 . It may be possible to operate the device facing upwardly towards a downwardly facing surface. This may be possible especially where the operational dimensions of the device are very small, such that forces in the liquid interface exceed inertial forces. Gravity does not affect operation of such a device. It may be possible therefore to use such devices in reduced gravity environments.
Confinement of the liquid 70 on the surface 80 is achieved via geometry and wettability of the device. The base 130 of the extension facing the surface 80 is made more wettable by the liquid 70 . However, side walls 110 - 120 of the extension are made less wettable by the liquid 70 . The liquid 70 does not spread out because of the right angle between the side walls 110 - 120 and the surface 80 and because of the less wettable properties of the side walls 110 - 120 . This confines the liquid 70 on the surface 80 to an area roughly corresponding to the area of the flow path 40 . Surfaces 200 and 210 of the base 130 are preferably made as small as practical in the interests of minimizing the area of the surface channel 100 which is not subject to flow of the liquid 70 .
Confinement of the liquid 70 on highly wettable surfaces is enhanced by positioning the flow path 40 on the extension from the body 10 . Further enhancement in liquid confinement is achieved by maximizing the contrast in wettability between the more wettable and less wettable sides of the device. Where applications of interest involve only moderately wettable surfaces, the extension alone may achieve liquid confinement and accordingly the aforementioned wettability contrast may be reduced or omitted. Alternatively, in some applications, the extension from the body 10 may be omitted and liquid confinement achieved by the wettability contrast alone.
Referring to FIG. 3 , the second opening 60 provides a capillary or meniscus pressure. This pressure exerts a negative second opening pressure OP 2 <0 on the liquid 70 in the flow path 40 . OP 2 <P 1 . Thus, when the liquid 70 reaches the second opening 60 , it is drawn into the second opening 60 and propelled toward the second port 30 . In turn, the second port 30 exerts a negative pressure P 2 <0 on the liquid 70 . P 2 <P 1 . Thus, P 2 supports a flow of the liquid 70 from the first port 20 to the second port 30 . The flow rate is a function of the ratio (P 1 -P 2 )/Fr, where Fr is the flow resistance of the liquid 70 flowing from the first port 20 to the second port 30 .
FIG. 4 shows a cross section through the device in a direction orthogonal to the flow path 40 . Similarly to side walls 110 - 120 , side walls 140 - 150 are less wettable to prevent spreading of the liquid 70 beyond the surface channel 100 . The capillary pressure retains the liquid 70 in the surface channel 100 .
Referring to FIG. 5 , if the gap increases, the magnitude of CP reduces. Eventually, CP reaches a threshold value. Below the threshold value, the liquid in the surface channel 100 drains first into the second port 30 and, provided that P 1 <0, into the first port 20 shortly thereafter. The drainage causes disruption of the flow of liquid 70 from the first port 20 to the second port 30 . The flow of the liquid 70 from the first port 20 to the second port 30 can be curtailed simply by disengaging the device from the surface 80 . It is thus possible to initiate flow of liquid 70 from the first port 20 to the second port 30 by engaging the device with the surface 80 and to stop the flow by disengaging the device from the surface 80 .
In a particularly preferred embodiment of the present invention, the flow path 40 is around 100 micrometers long and 100 micrometers wide, and the surface channel defining protrusion 90 extends from the base of the device by between 1 and 10 micrometers. The volumes of the first port 20 and the second port 30 are 500 nanoliters each. The depth of the surface channel 100 cannot exceed the width of the surface channel 100 . The maximum depth of the surface channel 100 is equal to the width of the surface channel 100 . It will appreciated that, in other embodiments of the present invention, SALT devices may have different dimensions.
The liquid 70 may contain treatment agents for processing a particular area of the surface 80 . Engaging the device with the surface 80 causes the treatment agent to flow over the region of the surface 80 facing the flow path 40 from the first port 20 to the second port 30 . The region of the surface 80 facing the flow path 40 is thus exposed to the treatment agents.
The process herein before described with reference to FIGS. 1 to 5 can be repeated multiple times to treat different regions of the surface 100 or different surfaces. The flow of liquid 70 restarts each time the device engages the surface 80 and stops each time the device is disengaged from the surface 80 . The supply of liquid 70 can be replenished as necessary via the first port 20 .
The aforementioned treatment agents may be molecules. SALT devices embodying the present invention are thus useful in the bio-patterning of surfaces. However, SALT devices embodying the present invention are not limited in application to delivery of molecules or the like to defined regions of a surface. Other types of liquid may be employed depending on the surface processing desired. SALT devices may be employed to sequentially deliver different treatments to a defined region of a surface. Examples of possible liquids include etchants and the like for producing localized chemical reactions on a surface. Such SALT devices may be reused repetitively, replenishing the supply of liquid as necessary. Process parameters associated with the treatment of the surface can be controlled via pressure difference, liquid viscosity, dimensions of the openings 50 and 60 , surface channel dimensions, and contact time.
Referring to FIG. 6 , in a preferred embodiment of the present invention, a first flow controller 130 is provided in the first port 20 . In operation, the first flow controller 190 assists in establishing P 1 . The first flow controller may have many forms. However, in a particularly preferred embodiment of the present invention, the first flow controller 190 comprises a plurality of a capillary members extending into the first port 20 . In operation, the capillary members form a capillary network contributing to P 1 by exerting capillary action on the liquid 70 .
A second flow controller, similar in form to the first flow controller 190 , is likewise provided in the second port 30 . In operation, the second flow controller assists in establishing P 2 . The second flow controller may have many forms. However, in a particularly preferred embodiment of the present invention, the second flow controller also comprises a plurality of capillary members extending into the second port 30 . The aforementioned capillary members may have circular, hexagonal, square, or rectangular cross sections. Other cross sectional shapes are equally possible.
In embodiments of the present invention herein before described, the first and second flow controllers each comprise capillary members. However, in other embodiments of the present invention, the first and second flow controllers may each comprise a different form of capillary network, such as a network formed from mesh, porous, or fibrous material. Vacuum pumps may be alternatively employed to develop either or both of P 1 and P 2 in the first port 20 and the second port 30 respectively. Pumps can also permit interactive tuning of the flow of liquid 70 in singular SALT devices or in arrays of SALT devices collectively, individually, or in groups. However, such pumps add complexity to the device.
In a preferred embodiment of the present invention, the direction of flow of the liquid 70 can be selectively reversed by selectively reversing the pressure difference between the first port 20 and the second port 30 . Specifically, the P 1 can be selectively made greater in magnitude than P 2 . This can be achieved by, for example, selectively increasing the density of capillary members in the first port 20 by adding additional capillary members or by compressing the first port 20 . Alternatively, where P 1 and P 2 are generated via pumps, the pump pressures can be selectively reversed. Other techniques for reversing the pressure difference between the first port 20 and the second port 30 will be apparent to those skilled in the art.
In the preferred embodiments of the present invention herein before described, there is a single first port 20 and a single second port 30 . However, referring to FIG. 7 , in other embodiments of the present invention, there may be multiple first ports 160 - 170 coupled to a single second port 30 via a common flow path 40 . Different reactive agents may introduced to each of the first ports 160 - 170 for reaction within the flow path. The flow path 40 may thus act as a reaction chamber activated by proximity of the surface 80 . Similarly, there may be a single first port 20 coupled to multiple second ports via a common flow path 40 . Equally, there may be multiple first ports coupled to multiple second ports via a common flow path 40 .
Referring to FIG. 8 , in a particularly preferred embodiment of the present invention, the flow path 40 has a curved cross section to prevent unwanted liquid retention, and residual flows between the first port 20 and the second port 30 .
With reference to FIG. 9 , in another preferred embodiment of the present invention, the flow path 40 has a rectangular cross section. This may lead to residual flow along corners of the flow path 40 when separated from the surface 80 . Such residual flows may prevent concentration of reagents by evaporation of the liquid 70 from the opening 50 . The capillary pressure of the flow path 40 when remote from the surface 80 can be optimized by tuning wettability and geometry together with P 1 and P 2 to prevent unwanted liquid retention and to limit the residual flow to a desired value.
Referring now to FIG. 10 , in a modification of the preferred embodiment of the present invention herein before described with reference to FIG. 1 , the flow path 40 is bounded by a peripheral flange 180 . In operation, the flange 180 seals to the surface to further prevent the liquid spreading from the flow path 40 . The flange 180 also serves to define the thickness of the surface channel 100 formed when the device is engaged with the surface 80 . The interior of the flange 180 may be wettable to facilitate contact between the liquid 70 in the first opening 50 and the surface 80 an thus to initiate flow of the liquid 70 between the first port 20 and the second port 30 . In such circumstances, the flange 180 performs the function performed by the protrusion 90 in the FIG. 1 embodiment. The protrusion 90 may thus be retained or omitted from the FIG. 9 embodiment. Alternatively, the flange 180 may be held at a small distance from the surface 80 once flow is established for example.
In the preferred embodiments of the present invention herein before described, features defining the surface channel 100 , such as the protrusion 90 and the flange 180 are integrated into the device. It will be appreciated however that, in other embodiments of the present invention, features defining the surface channel 100 may be provided by formations of the surface 80 .
With reference to FIGS. 11 and 12 in combination, in a preferred embodiment of the present invention, a device as herein before described may be aligned with a surface 80 patterned with more wettable areas 81 surrounded by less wettable areas 85 - 88 . The flow path 40 and the more wettable area 81 are matched in size and aligned with each other to define the surface channel 100 . The less wettable areas 85 - 88 help confine the liquid 70 in the surface channel 100 , which is the region perpendicular to the flow path 40 . It will be appreciated that defining the surface channel 100 by more wettable areas 81 that match and can be aligned with the flow path 40 increases flexibility in design of the device and relaxes constraints of the level of wettability contrast.
In the preferred embodiments of the present invention herein before described, flow initialization is effected by the protrusion 90 or by the flange 180 . However, in other embodiments of the present invention, flow of the liquid 70 along the flow path 40 may be initialized by other techniques. For example, in another embodiment of the present invention, the device has no protrusion 90 or flange 180 adjacent the first opening 40 . To initialize flow of the liquid 70 , the base of the device is first brought into contact with the surface 80 so that the liquid 70 in the first opening contacts and wets the surface 80 . The device is then withdrawn from the surface to a distance equal to the desired depth of the surface channel 100 . Capillary pressure in the surface channel 100 then transports liquid from the first port 20 to the second port 30 until the liquid reaches the second port 30 , whereupon the pressure difference between the first port 20 and second port 30 maintains the flow.
Referring to FIG. 13 , this technique is particularly useful for flowing the liquid over a raised area of the surface 80 .
Referring to FIGS. 14 and 15 in combination, in this embodiment of the present invention, the side walls 220 - 230 and 260 - 280 of the raised area and the surrounding region 240 - 250 of the surface 80 are non-wettable by the liquid 70 . Thus, the raised area of the surface channel 80 together with the flow path 40 of the device define the surface channel 100 . It will be appreciated that a protrusion may be provided on the raised area of the surface 80 to help initiate flow. Comparing this embodiment of the present invention with that herein before described with reference to FIG. 1 , it will be appreciated defining the surface channel via a raised area of the surface increases flexibility in design of the device.
With reference now to FIG. 16 , in a preferred embodiment of the present invention, the first port 20 and/or second port 30 of the device may be loaded and/or unloaded with the liquid 70 from below via the openings 50 and 60 . Lids may be provided to close the first port 20 and the second port 30 . The lids may be permanently sealed so that liquid can be introduced to the device via the openings 50 and 60 alone. The openings 50 and 60 may likewise be provided with lids to prevent evaporation during periods of nonuse. A reservoir device 510 comprising a reservoir 520 for the liquid 70 may be provided for filling, refilling, and draining the applicator device. The reservoir device facilitates loading and unloading of the first port 20 and the second port 30 of the applicator device independently without requiring removal of the lid. In operation, the reservoir device 510 forms a flow path 101 between the reservoir 520 and the first port 20 or the second port 30 depending on location of the reservoir device 510 relative to the applicator device.
Embodiments of the present invention have been described herein with reference to a SALT applicator device having less wettable and more wettable surfaces. The initiation and confinement of the flow of the liquid 70 is achieved and controlled via synchronization of pressures exerted on the liquid 70 at different locations, such as in the first and second ports 20 - 30 , in the opening 50 - 60 , and along the flow path 40 . The confinement of the liquid 70 by interfacial tension is a function of surface wettability and geometrical parameters in combination. The confinement pressure involved can be achieved by only a small wettability difference between faces of the device, or, in some cases, with zero wettability difference. This is possible because the geometry of the device and/or surface can be employed to confine the liquid 70 . Preferable confinement conditions can be obtained by superposing a wettability pattern on top of the geometry. The confinement conditions can be calculated analytically by taking into account contact angles of the liquid 70 with the faces, surface tension in the liquid, pressures and flow rates.
In another embodiment of the present invention, flow initialization is achieved by located the device proximal to the surface 80 in a humid environment. In this arrangement, the device and/or the surface may be initially cooled down to promote condensation, thereby further stimulating flow. Alternatively, an electric field may be applied between the device and the surface in the interests of stimulating the liquid 70 in the first opening 50 to contact the surface 80 . Similarly, a pressure pulse may be applied to the liquid 70 in the first opening 50 likewise to stimulate contact with the surface 80 . Alternatively, a heat pulse may be applied to the liquid 70 to initialize the flow of the liquid from the first port 20 to the second port 30 via vaporization of the liquid 70 .
Preferred embodiments of the present invention have been herein before described with reference to a single SALT device. However, it will be appreciated that many such devices may integrated to form a SALT array. Referring to FIGS. 17 and 18 for example, 12 such SALT devices may be integrated into a single 3×4 SALT array of devices. It will be appreciated that many different configurations of SALT array are possible, involving different numbers of SALT devices.
Referring now to FIG. 19 , in yet another embodiment of the present invention, the ports of several SALT devices 370 - 390 are interconnected t form a cascade of SALT devices. By generating a less negative pressure in port 420 and a most negative pressure in port 432 , liquid flows from port 420 via a first surface channel to port 421 , and from port 421 via an interconnection to port 430 . From port 430 , the liquid flows via a second surface channel to port 431 , and from port 431 the liquid flows via a third surface channel to port 432 . In a particularly preferred embodiment of the present invention, each of the ports 420 - 432 forms a reaction chamber in which the liquid reacts. The product of such reactions may be analyzed in each of the ports 421 and 431 or in the final port 432 on completion of the reaction. Alternatively, the product of such reactions may be analyzed on the surfaces 370 - 390 . In another alternative, the products of such reactions may be used to treat or react with the surfaces 370 - 390 .
Preferred embodiments of the present invention have been herein before described with reference to a SALT device having a body 10 formed from an elastomeric or rigid material. Such materials can be shaped by well-known microfabrication techniques, such as photolithography, etching, injection molding and the like. Embodiments present invention based on such materials may be of unitary construction However, it will also be appreciated that the present invention may be implemented by an assemblage of multiple parts. For example, embodiments of the present invention may also be of a layered assembly. Each layer may formed from a different material such as elastomer, silicon, SU-8, photoresist, thermoplastics, ceramic, and metal.
Placement of a device embodying the present invention relative to a surface may be achieved via a manipulator. Such a manipulator may be manually controlled or automatically controlled via a programmable computer or similar electronic control system. Such a manipulator may act upon the device, the surface or both, providing control of in plane and/or out of plane translational and/or rotational motions. Such manipulators may permit an increase in frequency with which one or more applicator devices embodying the present invention may be engaged with a surface concurrently. | A device for flowing a liquid on a surface comprises: a flow path. A first port supplies the liquid to one end of the flow path and applies a first port pressure for retaining the liquid when the flow path is remote from the surface. A second port receives the liquid from the other end of the flow path and applies a second port pressure such that the difference between the first and second negative port pressures is oriented to promote flow of the liquid from the first port to the second port via the flow path in response to the flow path being located proximal to the surface and the liquid in the device contacting the surface. The first and second port pressures are such that the liquid is drawn towards at least the second port in response to withdrawal of the flow path from the surface. Such devices may employ microfluidic technology and find application in surface patterning. | 8 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a reactive geocomposite for controlling or preventing the further spread of contaminants in soil or water. More particularly, the geocomposite described herein includes a reactive core formed from a high loft geotextile that is filled with a powdered or granular reactive material, such as activated carbon, coke breeze, peat moss, polymeric ion exchange resins, polymeric adsorbing resins; zero-valent iron, apatite, organophilic clay, zeolite, diatomaceous earth or mixtures thereof and having a liquid-permeable cover sheet attached to the upper and lower major surfaces of the filled geotextile.
BACKGROUND AND PRIOR ART
[0002] The prior art is replete with methods and articles used to confine or store a wide variety of environmental contaminants ranging from completely capping, in-situ, contaminated sediments that are left in-place in underwater environments; terrestrial landfills wherein dredged or otherwise collected contaminated sediments are placed within an engineered disposal site surrounded with an impervious liner system and capped with an impervious material; and the use of a reactive mat and/or reactive backfill that surrounds the contaminated material. Examples of reactive mats are found in U.S. Pat. No. 6,284,681 B1 ('681) and published application U.S. 2002/0151241 A1 ('241). The reactive mats described in these two publications include one or more layers of reactive material each surrounded by geotextiles that allow contaminated liquid to pass through the reactive mat for sorption or reaction of the contaminate with a reactive material contained between the geotextile layers, and in the case of the '241 published application, the mat may be deployed vertically.
[0003] One of the major problems encountered with the use of reactive mats for controlling or confining contaminated materials, or in controlling or preventing leaching of contaminants from sediments and preventing the contaminants from entering ground water supplies or from traversing through a lake or ocean soil interface into the lake or ocean, is in the ability to provide a transportable mat having a sufficient volume or thickness of reactive material so that the mat provides very long term protection without the necessity of periodic replacement. The reactive mats described in the '681 patent and in the '241 publication provide alternating layers of geotextile/reactive material/geotextile/reactive material since a sufficient thickness of reactive material cannot be provided in a single reactive material core layer without that reactive material being lost during transportation or installation.
[0004] This assignee's U.S. Pat. Nos. 5,237,945 ('945) and 5,389,166 ('166) describe the manufacture of a water barrier formed from a clay-fiber mat that may include, intermixed with a powdered or granular bentonite clay, a powdered or granular liquid-interacting material, e.g., a contaminant-reactant, or providing the contaminant-reactant as a separate layer in the water barrier product. The water barrier mat formed in accordance with the '945 and '166 patents is manufactured by laying down geosynthetic fibers and the water swellable clay, with or without the contaminant-reactant material, simultaneously. In this manner, a geosynthetic composite material can be manufactured wherein the geosynthetic fibers are surrounded by the water-swellable clay, with or without the contaminant-reactant material, in initially forming a relatively thick geotextile. Such a mat must be subsequently consolidated after the initial formation of the mixture of powdered or granular material and fibers in an attempt to secure the fibers in position surrounding the powdered or granular material. The following problems may be encountered with filled mats manufactured by simultaneously mixing individual fibers together with powdered or granular materials in accordance with this assignee's U.S. Pat. Nos. 5,237,945 and 5,389,166:
[0005] (1) Because interior fibers within the geotextile are not secured to adjacent fibers, particularly in thick mats, there would be lateral movement of powdered or granular material within the mat, particularly at the center of the mat thickness; (2) Any reactive materials that have a relatively high hardness, e.g., coke breeze, will prevent needle-punching as a means to consolidate the mats described in the '945 and '166 patents, since the hard materials will cause needle breakage and frequent replacement of worn needles; (3) Needle-punching as a means to consolidate the '945 and'166 mats is limited to relatively thin mats, e.g., less than 1 inch or 2.54 cm (25.4 mm), since fibers are too short to traverse the thickness of thicker mats for effective connection; and (4) Because of the shifting of fibers and powdered or granular material during manufacture of the '945 and '166 mats, the powdered or granular material will not be placed within the mat in a consistent quantity (weight per unit volume) and, therefore, will not provide consistent contaminant reaction, contaminant sorption, or contaminant neutralization per unit area. Another issue with the '945 and '166 mats is that when water swellable sodium bentonite clay is utilized, with or without the reactive material, when the sodium bentonite clay swells, the resulting swell pressure restricts the aqueous flow through the mat.
SUMMARY
[0006] In brief, described herein are reactive geocomposite mats, and their method of manufacture, for controlling contaminants in soil or water that allow the passage of essentially non-contaminated water therethrough. The geocomposite mat includes a pre-formed woven or non-woven geotextile, having a thickness of about 6 mm to about 200 mm, preferably about 10 mm to about 100 mm, and having a porosity sufficient to receive a powdered or granular contaminant-reactive material, contaminant-sorptive material, or a contaminant-neutralizing material (hereinafter collectively referred to as “contaminant-reactant material” or “contaminant-reactive material”) throughout its thickness, or in any portion of the thickness, across its entire major surface(s). The powdered or granular contaminant-reactive material is disposed within the pores of the previously formed, high loft geotextile mat to surround the fibers, e.g., by vacuum suction or by vibrating the high loft mat while in contact with the contaminant-reactive material to allow the powdered or granular contaminant-reactive material to flow, by gravity and vibrational forces, into the pores of the previously formed geotextile. Liquid-permeable cover sheets are adhered to the upper and lower major surfaces of the filled geotextile to prevent the powdered or granular material from escaping from the geotextile during transportation and installation. Optionally, the edges of the filled geotextile can be sealed, such as by providing the upper and lower cover sheets slightly larger than the dimensions of the geotextile and gluing the extra cover sheet material to the edges of the filled geotextile or heat sealing them together. Other edge sealing options include sewing, needlepunching, and ultrasonic welding of the cover sheets together or by applying a separate, edge-covering material that can be glued, heat sealed or ultrasonically welded to the cover sheets. Edge sealing materials may be liquid-impermeable or liquid-permeable.
[0007] Suitable powdered or granular contaminant-reactive materials include organophilic clay, activated carbon, coke breeze, zero-valent iron, apatite, zeolite, peat moss, polymeric ion exchange resins, polymeric adsorbents and mixtures thereof. If the contaminant-reactive material is lighter than water, where the reactive mat is intended for sub-aqueous disposition, such as activated coke breeze, the geotextile fibers will be a material that his heavier than water, such as a polyester. Any geosynthetic fibers may be used where the reactive material is heavier than water, such as polyolefins, e.g., polypropylene, polyethylene and copolymers thereof; rayon; polyesters; nylon; acrylic polymers and copolymers; polyamides; polyamide copolymers; polyurethanes, and the like.
[0008] The method of manufacture permits the manufacture of a geocomposite article that includes a contaminant-reactant material that is structurally secure, without lateral movement, and contains contaminant-reactant material uniformly disposed throughout the thickness, or throughout a desired upper and/or lower portion of the thickness of the geocomposite. The geocomposite can be manufactured to provide either a flexible or a rigid geocomposite material, and permits the manufacture of various modified geocomposites; geocomposite articles that include a contaminant-reactant material, such as a zeolite or an organophilic clay with or without a water-absorbent material for treatment of contaminants in water, in an organic liquid, or in a mixture of water and an organic liquid; a minimum of leakage of powdered or granular materials held by the pre-formed mat; the application of layer(s) of liquid-permeable films or sheets of material over both major surfaces of the article to confine the granular or powdered material in place within the pre-formed geotextile; the application of solid or liquid adhesive materials or compositions to one or both major surfaces and/or to any of the edges of the geocomposite article for complete retention of essentially all powdered and/or granular materials; the capability of inserting one or more rigidifying materials into, or onto, the geocomposite article during manufacture, such as a sheet of perforated fiberglass; rope; cardboard; relatively rigid, liquid-permeable corrugated materials, e.g., corrugated cardboard, and the like at some point at or between the top and bottom major surfaces of the geocomposite article to provide various degrees of flexibility or rigidity; the capability of manufacturing the geocomposite articles without the necessity of a consolidation step; and providing various sizes, shapes and weights of pre-formed, high loft geotextiles to achieve the benefits of each. If a water-absorbent, water-swellable material, such as sodium bentonite is included with the contaminant-reactive material, it should be included in an amount less than about 20 lb/ft 3 , preferably 0 to about 10 lb/ft 3 , more preferably 0 to about 5 lb/ft 3 so that, upon swelling, it does not prevent the flow of contaminated water through the geocomposite mat.
[0009] The contaminant-reactant material can be withheld from an upper or lower major surface of the high loft geotextile, if desired, to provide a space or area for the contaminant-reactant material to expand upon reaction or sorption with, or neutralization of the contaminants; or to provide areas for the addition of other powdered or granular materials, such as an organophilic clay, a zeolite or other contaminant-treating material. For example, the contaminant-reactant material can be omitted throughout a predetermined thickness at the top major surface or the bottom major surface. Alternatively, a powdered or granular water-swellable clay material can be applied in a relatively high concentration at or near the edges of the geocomposite article adjacent to one or both major surfaces to permit the contaminant-reactant material layer to extrude through a water-permeable cover layer to a planar edge surface immediately above and/or below one or both exterior major surfaces, thereby creating a sealing layer of contaminant-reactant material capable of sealing at overlaps and seams between adjacent or overlapping geocomposite articles.
[0010] As shown in FIG. 6 , it is preferred to seal the edges 193 of the filled geocomposite articles 10 by providing excess cover material 192 and/or 194 in an amount sufficient so that one or both of the cover layers 192 and/or 194 can be overlapped and adhered together, at or above the edge 193 , via an adhesive, thermal bonding (heat-sealing), needle punching, or sonic welding.
[0011] Accordingly, one aspect of the geocomposite articles described herein is to provide a new and improved article of manufacture and method of making the article by incorporating a powdered or granular contaminant-reactant material into a high loft, pre-formed mat of interconnected, geotextile fibers.
[0012] A further aspect of the geocomposite articles described herein is to provide a new and improved article of manufacture including a powdered or granular contaminant-reactant or contaminant-interacting material, wherein the material is selected from the group consisting of an organophilic clay, a zeolite, a contaminant-absorbent, a contaminant-adsorbent, an ion-exchange material, a contaminant-reactant, a contaminant-neutralizing material, and mixtures thereof as separately applied or intermixed material. The powdered or granular materials may be applied as an admixture, or applied sequentially within a pre-formed textile mat having a sufficient apparent opening size, e.g., about 0.5 to about 6 mm, preferably about 1 mm to about 4 mm, to receive the powdered or granular material in an amount of at least about 10 lb/ft 3 up to about 150 lb/ft 3 , preferably about 30 lb/ft 3 to about 100 lb/ft 3 , throughout the thickness, or throughout any upper or lower portion of the thickness of the pre-formed mat. Preferably, the powdered and/or granular material will occupy about 50% to about 99.9% by volume of the pre-formed geotextile mat, more preferably about 80% to about 99.9% of the pre-formed mat.
[0013] The above and other aspects and advantages of the geocomposite articles and their method of manufacture will become apparent from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 and 3 are partially broken-away, schematic views of alternate methods of manufacture and apparatus used to make the geocomposite articles described herein;
[0015] FIG. 2 a is an enlarged, partially broken-away side view of a reactive geocomposite article formed with upper and lower layers of powdered or granular contaminant-reactant material;
[0016] FIG. 2 b is an enlarged, partially broken-away side view of a reactive geocomposite article of that has been filled with a powdered or granular contaminant-reactant material, such as an organophillic clay, over the entire thickness of the mat;
[0017] FIGS. 4 a , 4 b and 4 c are enlarged, broken-away side views of articles manufactured as described herein that include intermediate liquid-permeable sheets or nets of strengthening materials and include a powdered or granular contaminant-reactant material in only a portion of the thickness of the article;
[0018] FIG. 5 is a perspective view showing the geocomposite article described herein oriented vertically, adjacent to a sea/soil interface, for sorbing contaminants, e.g., hydrocarbons from a petroleum fraction, that leach through soil and travel through the sea/soil interface, into the sea, to prevent the contaminants from traversing the sea/soil interface; and
[0019] FIG. 6 is a partially broken-away side view of an edge of the geocomposite article having excess material from upper and lower cover sheets adhered together, either adhesively, by heat-sealing, or by ultrasonic welding, to seal the edges of the article.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Turning now to FIG. 1 , there is shown a schematic diagram for manufacturing the geocomposite articles 10 described herein, including many optional features any one or more of which can be included in the manufacturing process to provide various characteristics and properties to the geocomposite articles.
[0021] The geocomposite article 10 is manufactured to include a layer of woven or non-woven liquid-permeable sheet material 12 and 14 on both major exterior surfaces; various reinforcing material can be included within the interior and/or exterior of the article to provide structural reinforcement or to provide various degrees of article rigidity; portions of the high loft geotextile 15 , along its upper and/or lower major surfaces can be left with low concentrations of, or without, a powdered or granular material so that a portion of the article is very porous to allow for venting of gases captured by the article from below; and powdered or granular materials such as a contaminant (organic) reactant absorbent or adsorbent, and, optionally a water-absorbent material, such as bentonite clay can be intermixed with the contaminant-reactant material(s) 16 being deposited onto the pre-formed, high loft geotextile 15 . Any of these features can be used alone or together with any of the other features, as best shown in FIGS. 1 and 3 , to provide very unique geocomposite articles having any number of different properties and the capability of containing the spread of contaminants.
[0022] As shown in FIGS. 1 and 3 , there is illustrated a method and apparatus, including a number of optional features each of which can be used alone or in combination with any of the other features for manufacturing a product having single or plurality of different granular or powdered contaminant-reactant materials, and with or without various reinforcing materials and/or coating materials added to one or both exterior surfaces of the article being manufactured to provide various characteristics or properties to the finished geocomposite article 10 , as will be described in more detail hereinafter. The apparatus generally includes a conveyor belt 17 that travels continuously around a pair of rollers 18 and 20 , at least one of which is motor driven at a desired speed; and one or more contaminant-reactant feeding devices, generally designated by reference numerals 22 and 24 .
[0023] The liquid-permeable sheet material layers 12 and 14 , used to prevent loss of the powdered or granular material during transportation and installation, are applied to the upper and lower major surfaces of the pre-formed, high loft geotextile after loading the geotextile 15 with contaminant-reactant material. The preferred method of manufacture is to first adhere the lower liquid permeable sheet material 12 to the high loft geotextile 15 then fill the high loft geotextile 15 with the powdered or granular material, followed by adhering the upper, liquid-permeable sheet material 14 to the high loft geotextile containing the powdered or granular material. In one embodiment, the powdered or granular material 16 penetrates the high loft geotextile 15 by vibrating the geotextile 15 with vibrator 140 . Alternatively, vacuum can be applied under the geotextile 15 .
[0024] Additional contaminant-reactant material in granular or powdered form can be applied to the filled geotextile 15 from feeding conduit 24 to provide one or more surface concentrations of contaminant-reactant material or to apply a different powdered or granular contaminant-reactant, prior to applying the water-permeable cover layers 12 and 14 . Upper and lower major surfaces then are covered with the water-permeable, preferably non-woven, cover layers 12 and 14 , from rolls 28 and 30 , that are preferably adhered to the major surfaces of the geotextile 15 using a water-insoluble adhesive, applied from adhesive supply vessels 32 and 34 .
[0025] Additionally, slicing or searing devices 36 and/or 38 can be provided above and/or below the article to provide extrudability to the contaminant-reactant material from the article, e.g., for sealing a plurality of the geocomposite articles at overlaps. The slicing or searing devices 36 and/or 38 can be used to slice and/or sear one or both of the cover layers 12 and/or 14 , at any point during the manufacture of the article 10 , for improved extrusion to provide seam and/or overlap sealing of adjacent articles, or the slicing step can be bypassed. The finished article 10 can be collected in a roll form 40 taken up on a suitable mandrel 42 or can be festooned onto pallets (not shown) or the like.
[0026] FIG. 2 a shows high loft geotextile mat 15 filled only on upper and lower major surfaces with the powdered or granular material 16 . FIG. 2 b shows the high loft geotextile mat 15 filled with a powdered or granular material 16 incorporated throughout the geotextile mat 15 .
[0027] Turning now to FIG. 3 , there is shown a schematic diagram of one method of loading the pre-formed, high loft geotextile mat 115 with powdered or granular contaminant-reactant material in a dry state. The dry material feeding apparatus, generally designated by reference numeral 100 is useful for depositing one or more powdered or granular contaminant-reactant materials, such as an organophillic clay, from a receiving hopper 102 . An auger 104 is disposed at a lower end of the receiving hopper 102 , and in fluid communication therewith, to force the contaminant-reactant material through conduit 106 to an inlet 108 of elevator 110 . The contaminant-reactant is discharged from the elevator 110 at elevator outlet opening 112 , through conduit 114 into a receiving hopper 116 . A pair of augers 118 and 120 in fluid communication with a lower portion of hopper 116 force the contaminant-reactant into one, two or three feeding mechanisms, generally designated by reference numerals 122 , 124 and 126 , for feeding the contaminant-reactant material in a controlled manner to one, two or three continuous feed conveyor belts 128 , 130 and 132 successively aligned above an elongated product conveyor belt 134 . The contaminant-reactant generally is applied over the high loft, geotextile mat 115 to substantially fill the void spaces between fibers in the high loft, geotextile mat 115 in an amount of about ¼ to 30 pounds of powdered or granular material per square foot of finished article major surface area, preferably about ¼ to about 5 pounds of powdered or granular material per square foot of article major surface area. In accordance with one embodiment, a supply of a liquid-permeable flexible sheet material 136 in roll form 138 is disposed above the continuous product conveyor belt 134 to provide a continuous supply of liquid-permeable flexible sheet material onto an upper surface of the product conveyor belt 134 . The upper surface of sheet material 136 from roll 138 is sprayed with liquid adhesive from adhesive vessel 139 to adhere the sheet material to an under surface of the high loft geotextile 115 , and the geotextile 115 then is filled with the powdered or granular material, from one or more of the feeding mechanisms 122 , 124 and/or 126 , deposited onto the geotextile 115 from one, two or all three of the feed conveyor belts 128 , 130 and 132 . Any one, two or all three of the feed conveyor belts 228 , 230 and 232 can be used to incorporate the same or different powdered or granular contaminant-reactant materials throughout a portion of, or the entire thickness of the geotextile 115 . Vibration apparatus 140 is connected to the product conveyor belt directly below the feed conveyor belts 128 , 130 , and 132 to vibrate the powdered or granular contaminant-reactant materials into the geotextile 115 .
[0028] The individual powdered or granular materials are deposited across the entire width of the geotextile mat 115 , as the particles drop from the feeders 122 , 124 and/or 126 . In this manner, the entire thickness or any portion of the thickness of the fibrous mat 115 is filled with the contaminant-reactant material. Dust collection suction devices 144 , 146 and 148 may be disposed near each continuous contaminant-reactant feed conveyor belt 128 , 130 and 132 to clear the air of fine particles emanating from feeding mechanisms 122 , 124 and 126 and return the particles back to a dust collector 167 for disposal and/or back to the receiving hopper 102 , via conduit 149 . A second flexible, water-permeable sheet material 150 , from roll 151 , is disposed on a downstream side of the clay feeding mechanisms 122 , 124 , and 126 and above the product conveyor belt 134 . The second flexible sheet material 150 is fed by power driven roller 152 , power rollers 154 and 156 and wind up rollers 158 and 160 to dispose flexible, water-permeable sheet material 150 on top of the contaminant-reactant-filled article to dispose the filled geotextile material 115 between lower flexible sheet material 136 and upper flexible sheet material 150 . Adhesive vessel 161 applies adhesive to a surface of sheet material 150 to adhere the sheet material 150 to an upper surface of the filled geotextile 115 .
[0029] The powdered or granular contaminant-reactant material utilized to fill the void spaces between the fibers of the high loft, geotextile has a particle size in the range of about 1 to about 400 mesh, preferably about 10 to about 200 mesh.
[0030] As shown in FIGS. 4 a , 4 b and 4 c , the articles of manufacture generally designated by reference numerals 170 , 180 and 190 , respectively, are manufactured to include a powdered or granular material, such as an organophillic clay 16 , incorporated into the geotextile 15 throughout only a portion of the overall thickness “t” of each article 170 , 180 and 190 . Each article 170 , 180 and 190 is shown to include an upper sheet or netting 192 and a lower sheet or netting 194 of liquid-permeable polymeric sheet material, rope, netting, or other strengthening, or rigidifying materials, the same or different, incorporated within the interior of the article during manufacture in any desired combination. The article 170 of FIG. 4 a includes the powdered or granular material 16 incorporated over a central portion of the article, defined between the two internal sheet or netting materials 192 and 199 . The article 180 of FIG. 4 b includes the powdered or granular material 16 in an upper portion of the article, above sheet material 192 , and under an upper, liquid-permeable sheet material 195 , as well as in a central portion of the article 180 , between sheet material 192 and sheet material 194 . The article 190 of FIG. 4 c includes the powdered or granular material 16 incorporated within a lower half of the article 190 , filling a lower portion of the article 190 between sheet material 194 , and lower, liquid-permeable sheet material 197 , and within a lower half of the central portion of article 190 between lower material 194 and upper material 192 . Such materials may be manufactured by adhesively securing multiple articles, filled or unfilled, each filled portion being manufactured in accordance with the description of FIGS. 1 and 3 .
[0031] Some of the most prevalent contaminants found in waste waters contained in ponds, lagoons, areas of subterranean structure and other water-releasing or organic (hydrocarbon) spill areas, particularly where these areas include industrial waste waters, are heavy metal ions and water-insoluble or partially water-insoluble organic materials. It is well known in the prior art that natural and synthetic zeolites and ion exchange resins are capable of removing a substantial portion of the heavy metal ions from a waste water solution and that organophilic clays are capable of removing water-insoluble organic materials from solution. However, the prior art suggests that removal of these materials from waste water streams should be done on-stream, treating the entirety of the waste water stream in order to remove these materials, requiring frequent replacement of treating materials because of the heavy volumes of waste water stream that passes through the zeolites or passes through the organophilic clays in order to clarify these waste water streams. By including an organophilic clay, or applying a mixture of water-swellable clay (not required) with a zeolite or organophilic clay, to fill the voids between fibers of the high loft geotextile 15 or 115 , the zeolite and/or organophilic clay will form a water-treatment material wherein the zeolite and/or organophilic clay will remove the contaminants, e.g., hydrocarbon contaminants, and allow the clean water to pass through the geocomposite article 10 .
[0032] As shown in FIG. 5 , the geocomposite articles 10 described herein are particularly effective for vertical disposition adjacent to a sea/soil interface 200 for protecting a lake or ocean 202 against hydrocarbon contaminants that otherwise leach through soil 204 and penetrate the sea/soil interface 200 .
[0033] In accordance with another important embodiment of the geocomposite articles described herein, the contaminant reactant material, comprising any contaminant-adsorbent, -absorbent, -reactant, or -neutralizing material can be supplied as a separate layer adjacent to another powdered or granular contaminant-reactant material so that the amount of material treated for the removal of a given contaminant is only that material which penetrates the adjacent layer of powdered or granular material.
[0034] In accordance with another important feature of the present invention, the contaminant-reactant materials mixed or supplied as separate layers can be any material capable of adsorbing, absorbing, neutralizing, or reacting with the contaminant for insolubilization and/or separation of the contaminant from the liquid stream flowing through the reactive material. Examples of materials capable of removing or neutralizing contaminants include absorbent fibers, such as microcrystalline cellulose; attapulgite clay; zinc rincinoleate absorbed on an absorbent fiber or other absorbent material; amorphous silica powder; synthetic calcium silicate; polyolefin pulp; sodium alumino-silicate (type A sodium zeolite); maltodextran; sodium silica aluminates (note that all the above are absorbents). Other materials, such as adsorbents include microcrystalline cellulose; silica hydrogel based compositions; attapulgites; synthetic sodium magnesium silicates; synthetic calcium silicates; silicon dioxide; acid activated clays; type A sodium zeolites; and the like provided as a separate layer or mixed with the absorbents and/or adsorbents. Other materials can be included such as an algicide, antimicrobial material, bactericide, disinfectant, and/or fungicides such as phenol; zinc undecylenate N.F.; acetyl tyridinium chloride N.F.X.III and the like.
[0035] Most preferred as the adsorbent, absorbent and/or reactant and/or neutralizing material are coke breeze, activated carbon, natural or synthetic zeolites, apatite, and/or an organophilic clay, which is basically a montmorillonite clay that has been reacted with a quaternary organic material to make it hydrophilic and absorbent to organic contaminants.
[0036] The high loft geotextile mat 15 or 115 can be woven or non-woven. Suitable fibers of construction of the geotextile mat 15 or 115 include fibers made from rayon, polypropylene, polyesters, nylon, acrylic polymers and copolymers, ceramic fiber, fiberglass, propylene-ethylene copolymers, polypropylene-polyamide copolymers, a single monofilament, polyethylene, polyurethane, cotton, jute and any other non-biodegradable, or very slowly biodegradable, fibers preferably having both bacteriological and chemical resistance. In some installations, the thickness of the article is not important and such articles can be formed with any desired thickness, e.g., 3 mils to about 4 inches containing about 0.2 to about 30 pounds per square foot of contaminant-reactant material.
[0037] The above-described products can be modified in a number of ways to suit various purposes and this adaptability of the products is one of the primary benefits when compared with water barriers of the prior art. For example, the geocomposite products described herein can be loaded with a heavy material such as metal screen, or a heavy mineral such as Barite, iron oxide or the like, relatively uniformly, together with a powdered or granular contaminant-reactant so that the overall product has a specific gravity greater than 1.0 thereby enabling the material to submerge easily in water. Accordingly, the product can be applied to the soil surface at the bottom of a filled lagoon, waste containment area, and the like, without first draining the lagoon or waste containment area. The product containing a heavy mineral can be rolled out over the water or waste containment upper level and allowed to sink to cover the soil surface at the bottom of the water or liquid waste material, thereby saving substantial time, effort and expense in sealing a pre-existing lagoon, waste containment area, and the like, without first draining the lagoon or waste containment area.
[0038] In another embodiment, the products described herein can have incorporated therein a very light material such as expanded vermiculite or expanded perlite, so that the product has substantial buoyancy in water, liquid waste materials, and the like, to form a cover over a liquid waste containment area, such as a toxic waste lagoon, to prevent external compounds, dust, and dirt from entering the waste containment area. One portion of this cover material can be adapted for removal or rolling back so that additional toxic waste and the like may be added to the covered containment area while maintaining a water-impervious cover to prevent further filling of the waste containment area with rain water.
[0039] The products described herein can be essentially a single non-woven fabric material, so that it can elongate, where elongation is a desirable characteristic, while retaining the desired contaminant-removal characteristics. Further, drainage structures and other articles used in the water drainage arts can be virtually incorporated into the interior of this product during manufacture, e.g., under the upper and/or lower cover sheets. Herbicides, bactericidal materials, tracer chemicals, various colorants that indicate contact with a particular chemical or class of chemicals, and the like, also can be incorporated into the articles described herein.
[0040] The product is particularly effective in shored wall conditions for application against steel sheet piling; soldier beam and lagging; soldier beam and earth installations; concrete caissons; earthen stabilized wall structures and diaphram wall structures. In addition to the usual geotextile-type fibers, cellulosic fibers can be used as well as hay, straw, coconut fibers and fibers refined from wood chips and the like, particularly for use as an agricultural root zone liner to provide liquid feed for the promotion of plant growth. The products described herein are also useful as gas barriers, particularly Radon gas barriers, to protect structures and containers above or below ground. Many other uses for the products of the present invention should be apparent to those skilled in the art.
[0041] The uses for the powdered or granular material-filled or partially-filled products described herein are virtually infinite since the product can be made completely flexible, relatively rigid or rigid and can be applied against very contoured and slopping surfaces, rough or smooth, as well as vertical surfaces, such as foundation walls, dams, along the sides of canals and below grades such as in tank farms, and for irrigation and water conservation techniques. The products are substantially better than layered products having an intermediate layer of powdered or granular material since the fabric of the present invention will not peel apart and the contaminant-reactant material has much less tendency to leak out of the product during handling and installation. Further, there is essentially no slippage of fabric since the product is, basically, a single non-woven fabric containing active material(s).
[0042] The products have a number of other advantages over the prior art layered products that include an upper and lower fabric surrounding an interior layer of bentonite clay since the products can be, essentially, a single fabric layer that is filled or partially filled with any desired powdered or granular contaminant-reactant material, while optionally including interior space for absorption or expansion of an interior powdered or granular material, such as a water-swellable clay. The products are particularly well suited for providing contaminant-removal in shored wall conditions to protect surface areas that are either vertical, sloped or horizontal. The products are very durable because of the method of manufacture, since strength is not dependent upon any method of structurally securing two separate fabric layers together across an intermediate layer of powdered or granular material. Such prior art layered products are significantly less durable than the products described herein because of their tendency to separate as a result of shear forces between top and bottom fabric layers, particularly where such layered products are installed over vertical or slopping surface, where shear forces are most prevalent. | Reactive geocomposite mats, and their method of manufacture, for treating contaminants in soil or water that allow the passage of essentially non-contaminated water therethrough. The geocomposite mat includes a pre-formed woven or non-woven geotextile, having a thickness of about 6 mm to about 200 mm, and having, a porosity sufficient to receive a powdered or granular contaminant-reactive material, contaminant-sorptive material, or a contaminant-neutralizing material (hereinafter collectively referred to as “contaminant-reactant material” or “contaminant-reactive material”) throughout its thickness, or in any portion of the thickness across its entire major surface(s). The powdered or granular contaminant-reactive material is disposed within the pores of the previously formed, high loft geotextile mat to surround the fibers, e.g., by vacuum or vibrating the high loft mat while in contact with the contaminant-reactive material to allow the powdered or granular contaminant-reactive material to flow by gravity into the pores of the previously formed geotextile and vibrational forces. Liquid-permeable cover sheets are adhered to the upper and lower major surfaces of the filled geotextile to prevent the powdered or granular material from escaping from the geotextile during transportation and installation. | 1 |
FIELD OF THE INVENTION
This invention relates to zero volt switching power converters.
BACKGROUND OF THE INVENTION
An important aspect of modern power supply design is the need to increase the power density of the power supply since many power applications involve locations in which the size of the power supply relative to its power output is restricted by space considerations. The power train and control circuits in addition to being highly compact must also have high overall efficiency to limit heat creating power dissipation. An illustrative application of a high density power supply is an off-line power supply used to power a laptop computer or similar appliance. Bridge type converters are suitable for such applications since they may be designed to operate resonately, which is an operational mode permitting a very high power density and high power efficiency.
The power switching transistors in a half bridge converter have an applied voltage stress half that of the switching transistors in a push-pull converter of comparable power handling capability. Hence the half bridge converter is especially suitable for high input voltage applications such as power converters powered directly from a rectified AC power line or from a power factor correction boost converter powered off the AC line.
SUMMARY OF THE INVENTION
A bridge topology power converter, embodying the principles of the invention, and operating in a resonant mode of operation is used as an off-line switching power supply operating with a high power density. A novel drive arrangement and operative scheme for driving the power switching transistors limits the dissipation losses within the power switching transistors. Two switching transistors are connected in a half-bridge configuration. Drive circuitry drives the two power switching transistors with unequal duty cycles having conducting durations such that the sum of the conduction intervals substantially equals the combined switching period of the two power switching transistors. These conducting intervals are separated by very short dead time intervals controlled by the differing turn-on and turn-off times of the two power switching transistors. The short interval between alternate conductions of the two power switching transistors is sufficient in duration to allow zero voltage turn on of the power switching transistors but short enough in duration to minimize power loss and conducted noise. In the illustrative embodiment the dead time is at least an order of magnitude less than the time interval of the shortest duty cycle. Regulation of the output of the converter is attained by adjusting the ratio of the first and second duty cycles or conducting intervals.
In addition a drive circuit for an FET power switch, operated according to the invention in a zero voltage switching mode, includes a circuit arrangement utilizing feedback of the current output of the discharging drain source parasitic capacitance to generate a voltage drop across a resistor in the gate circuit to clamp the gate below a turn-on voltage of the FET power switch. When the drain-source parasitic capacitance is discharged, the application of the turn on voltage to the gate is enabled.
BRIEF DESCRIPTION OF THE DRAWING
In the Drawing:
FIG. 1 is a schematic of a bridge type power converter embodying the principles of the invention;
FIG. 2 is a waveform diagram of voltage waveforms to assist in explaining the operation of the converter;
FIG. 3 shows representative gate voltage drive waveforms of the power switches to assist in explaining the operation of the converter;
FIG. 4 shows switching voltage waveforms of the power switches of the half bridge to assist in explaining the operation of the converter;
FIG. 5 shows switching voltage waveforms of the power switches to assist in explaining the operation of the converter;
FIG. 6 shows a magnetic model of integrated magnetics used in the converter;
FIG. 7 shows an electical model of integrated magnetics used in the converter; and
FIG. 8 shows voltage waveforms to assist in explaining the operation of the integrated magnetics.
DETAILED DESCRIPTION
A schematic of a DC to DC converter embodying the principles of the invention is shown in the FIG. 1. The converter 100 includes a half bridge power switching circuit 110, an integrated magnetics processing circuit 130, a synchronous rectifier 150, an output 160, and a control circuit 170.
Input power is applied to the input terminals 101 and 102. This input power may in the instant circuit be provided by a power factor boost converter connected to be energized by AC line voltage via a rectifier circuit. This input power is processed by the two power switches 111 and 112 (FET power switches in the illustrative embodiment), connected in a half bridge switching circuit arrangement, and coupled to the primary winding 132 of the transformer 133 included in the integrated magnetics processing circuit 150. Primary winding 132 is connected in series circuit with a capacitor 123. This series circuit is connected in parallel with the power switch 112. The average voltage across capacitor 123 is the same as the average voltage across the power switch 112. The secondary winding 134 of the power transformer 133 is connected, via a ripple canceling magnetic circuit including the inductors 135, 136 and 137, and the transformers 138 and 139 to a synchronous rectifier 150. Two FET rectifier devices 151 and 152 are connected to supply a rectified voltage to the output filter 160. The converter's DC voltage output is provided at the output terminals 161 and 162.
The DC output voltage of the converter at terminals 161 and 162 is sensed by the control circuit 170 and applied via leads 171 and 172 to a voltage divider comprising resistors 173 and 174. The divided voltage at a center node 175 of the divider is connected to an inverting input of an opamp 176. A reference voltage 177 is connected to its non-inverting input. The output of opamp 176 is a control error voltage which is representative of the deviation of the DC output voltage of the converter at terminals 161 and 162 from some preselected regulated voltage value.
The control error voltage is applied to the inverting input of a comparator 180. A periodic ramp voltage is applied to the non-inverting input by a ramp generator 181. The output of the comparator 180, on lead 183, is a rectangular voltage waveform with finite rise and fall times. Its duration or duty cycle (i.e. fraction of the voltage high with respect to the period) is controlled by the amplitude of the control error voltage.
A typical sawtooth waveform 201 supplied by the ramp generator is shown in the FIG. 2. A typical control error voltage level (i.e. its ordinate) is shown by the amplitude mark 202 on the vertical axis 203 of FIG. 2. The control output voltage of the comparator is a pulse signal with finite rise and fall times as shown by the waveform 205 in FIG. 2. Its high value duration (D) is governed by the time interval necessary for the positive sloped ramp 206 of waveform 201 to attain the value of the ordinate 202 of the error voltage level. Subsequently the output of the comparator is a low level for the remaining duration (1-D) of the increasing ramp waveform. The period of the ramp waveform (1) determines the period of operation of the converter. The respective conduction intervals as shown by the pulse 210 and intervening low states are of substantially different durations. The two power switches are enabled for unequal durations (D and 1-D) which differ substantially as shown by the waveform 205. The ratio of these two unequal durations are altered in response to the control error voltage in order to achieve regulation of the output voltage.
The waveform (205) generated by the comparator 180 is coupled, via lead 183 and capacitor 184, to the primary winding 114 of a transformer 115 of a gate drive 120. The capacitance of capacitor 184 is selected to block the DC portion of waveform 205 while leaving the pulse wave shape substantially unchanged.
The gate drive 120, shown in FIG. 1, includes the input transformer 115 having its primary winding 114 connected to receive the pulse waveform 205 (also shown as voltage waveform 301 in FIG. 3). The pulse waveform 205 is coupled to the two secondary windings 116 and 117 having winding orientations to supply voltages on these windings inverted in polarity relative to each other. These opposite polarity voltages are applied to the gate drive resistors 126 and 127, respectively. The pulse waveform applied to the gate resistor 126 is substantially identical to the waveform 205 shown in FIG. 2, while the waveform applied to the gate resistor 127 is the inverse of the waveform 205 (i.e. out of phase with the waveform 205). The respective duty cycles of the two switches do not take up the full allotted period due to the finite rise and fall times of the oppositely phased pulses.
Waveform 302 of FIG. 3 is the output of secondary winding 116 of the transformer 121. Waveform 303 of FIG. 3 is the output of secondary winding 117 of the transformer 121. The waveform 302 is in phase with the control waveform 301 and the waveform 303 is out of phase. The high state portions of the waveforms 302 and 303 drive the FET power switches 111 and 112 into their individual conduction states for the duration of the waveforms high state. Power switches 111 and 112 are conductive during opposing phase intervals and for the differing durations (D and 1-D).
The circuitry associated with each of the FET power switches is designed to apply a controlled time delay to the initial rise of the applied gate-source drive waveform. In the drive circuit for the FET power switch 111, the drive signal is applied via the secondary winding 116 of the transformer 115, a resistor 126, and a capacitor 128. The slewing of the voltage across FET power switch 111 causes current to flow through capacitor 128. This current causes a voltage to be developed across resistor 126. this voltage reduces the gate voltage of the FET power switch 111 and thereby operates to delay the rise time of the gate signal until the drain-to-source voltage, of FET power switch 111, reaches a minimum value. This drop to a minimum value occurs as a result in part to the effects of the leakage inductance of the transformer 133 as well as the effects of the magnetizing current of the transformer 133. This minimum voltage is limited by the clamp voltage of the parasitic diode of the FET power switch.
As the drain-to-source voltage of the FET power switch 111 is falling, current is drawn through the series resistor 126 and capacitor 128 delaying the rise time of the gate-to-source voltage (shown by waveform 401 in FIG. 4) until the drain-to-source voltage reaches its minimum value. Hence a small time delay (shown by time increment 403 in FIG. 4) occurs between the turn-off of the FET power switch 112 and the turn-on of the FET power switch 111. The FET power switch 111 is then turned-on at the minimum value of the drain-to-source voltage thereby minimizing the turn-on loss.
The drive circuit for the FET power switch 112 is energized by the output of the secondary winding 117 of the transformer 115. It includes a series connected resistor 127 and a capacitor 129. This series circuit operates, as described above with relation to application of the drive to the FET power switch 111, to delay rise of the gate-to-source voltage (shown by waveform 402 in FIG. 4.) at the gate of the FET power switch 112 until its drain-to-source voltage reaches a minimum value. (delay shown by time increment 404 in FIG. 4)
In each drive circuit the values of resistance for each of the resistors (126, 127) and values of capacitance for each of the capacitors (128, 129) is selected so that the current through the drain-to-source parasitic capacitor of the FET power switch develops a voltage sufficient to hold the gate-to-source-voltage below the turn-on threshold voltage value.
V.sub.drive -I*R<V.sub.threshold. (1)
The current is a function of the slew rate of the drain-to-source voltage and of the capacitance value.
I=C*dv/dt (2)
The capacitors 128 and 129 are sized and added to augment the already existing Miller capacitance which by itself is not sufficient to supply the needed capacitance value. The resistance value of the resistors 126 and 127 must be low in value to assure a fast rise in gate voltage when the capacitor current goes to zero value. The diodes 118 and 119 are added to provide a low impedance path for turn-off signals and enhance the turn-off efficiency of the power switches.
As described above the FET power switches 111 and 112 are driven out of phase with each other with a small dead time between unequal conducting intervals (D and 1-D) of the two power switches. The dead time occurring between the conducting intervals of the two switches is critical to the minimization of the switching losses.
If the switching period of the power converter is defined as unity (i.e. "1") the power switch 111 has a conduction duty cycle of "D" and the power switch 112 has a conduction duty cycle of "1-D". The voltage across the power switch 112 (as shown by waveform 501 in FIG. 5) is approximately zero volts for the substantially all of the "1-D" fraction of the switching period and equal to the input voltage Vin for substantially all of the remaining "D" fraction of the switching period. These voltage relations are clearly illustrated in the FIG. 5 wherein waveform 501 represents the voltage across the power switch 112 and the voltage waveform 502 represents the voltage applied to the primary winding 132 of the transformer 133. Waveform 503 represents the voltage across the capacitor 123 connecting the primary winding 132 to the return lead 138 connected to input lead 102. This voltage, shown by waveform 503, is substantially equal to the product of the interval "D" and the input voltage Vin. The average voltage across the primary winding 132 is zero for this switching period.
During the dead times 505 and 506 shown in FIG. 4, the leakage energy of the transformer 133 resonates with the parasitic capacitances of the power switches 111 and 112 forcing the voltage across a power switches to zero volts just prior to its turn-on. In addition to the leakage energy, the transformer magnetizing current acts to force the voltage across the power switches to zero volts just prior to turn-on. The inductive energy of transformer 133 forces its voltage to reverse when current flow is interrupted at the end of the conduction interval of the transistor switch 111 during the dead time 505. This transformer voltage reversal forces the voltage across transistor switch 112 toward a zero voltage value. Zero voltage switching is attained for the transistor switch 112 when the inductive energy is sufficient to force the voltage across transistor switch 112 to zero voltage before the start of the conduction interval "1-D". Similarly zero voltage switching for the transistor switch 111 is attained during the dead time 506 at the end of the conduction interval for transistor 112
Values needed for the magnetizing energy and leakage energy of transformer 133 in order to achieve zero voltage switching are dependent on the impedance of the converters secondary circuitry. In the present example (a half bridge buck type converter) the zero voltage switching is attained by setting the magnetizing current larger than the reflected output current or by setting the leakage energy larger than the energy needed to discharge the parasitic capacitances of the transistor switches 112 and 112.
During conditions of low output current, the effects of magnetizing current is dominant. During conditions of high output current, the effects of leakage energy is dominant. Zero volt switching may be obtained for the full range of output current by maximizing of both magnetizing current and leakage energy. This zero volt turn-on transition timing is obtained by the automatic adjustment of the dead time value through the novel gate drive circuit. The attainment of zero volt turn-on transitions minimizes power loss, and limits radiated and conducted noise.
In order to prevent the transformer 133 from saturating during operation of the converter due to the unsymmetrical drive applied to it, its core is typically gapped to accommodate the high magnetizing currents. The transformer 133 and the inductances 135, 136, and 137 are constructed in an integrated form. The equivalent magnetic core model 601 is shown in FIG. 6 and is the equivalent of a three leg magnetic core structure. The equivalent electrical model 701 shown in FIG. 7 and in FIG. 1 of the actual circuit includes a delta connected loop of three inductors 135, 136 and 137. The coupling of the transformer windings 134, 146 and 147 to each inductor 135, 136 and 137, respectively, is shown and is equivalent to the circuit arrangement of the integrated magnetics circuit 130 shown in the FIG. 1.
The integrated magnetics circuit 130 provides three reluctance paths for output current. During a first phase of the switching cycle the current output flows through the winding 146 which has the inductance 136. Current in the other half cycle flows through the winding 147 and its inductance 137. Since the respective duty cycles (D, and 1-D) are unequal the ripple currents are out of phase and cancel each other and hence the resultant ripple current is less than the ripple in any one of the inductors. If a particular operating point is predominant the values of the inductors 135, 136 and 137 may be specifically selected so that all the ripple currents are substantially canceled at the operating point when the ratio of the output inductances equals the ratio of the oppositely phased duty cycles. If the ratio of the inductances is selected to equal the voltages applied to them the current are out of phase and sum to zero and the ripple current is zero.
By properly selecting selecting values for inductors L 1 and L 2 , the ripple can be made to cancel at a defined load. where L 1 is inductor 136 and L 2 is inductor 137. For the D portion of the cycle;
V.sub.L1 =V.sub.out. (3)
and for the (1-D) portion of the cycle;
V.sub.L.sbsb.1 /V.sub.L.sbsb.2 =D/(1-D). (4)
Hence during the entire switching cycle the expression (6) substantially defines the voltage ratio across the inductors;
V.sub.L.sbsb.1 /V.sub.L.sbsb.2 =L.sub.1 /L.sub.2. (5)
These currents hence exactly cancel at the operating point when:
L.sub.1 /L.sub.2 =D/(1-D). (6)
During the interval of conduction of the FET power switch 112 the secondary inductor 137 of the integrated magnetics circuit 130 is connected to the output terminals 161, 162, via FET rectifier 151 of the synchronous rectifier circuit 150. The balance of the secondary voltage appears across the inductor 136. During the opposite phase of the conduction interval of FET power switch 111 the secondary inductance 136 is connected across the output voltage terminals 161, 162 through the synchronous rectifier switch 152. The remainder of the output voltage is developed across the secondary inductor 137.
The voltage waveforms of the integrated magnetics circuit are shown in the FIG. 8 The voltage waveform 803 is representative of the voltage across the secondary inductor 137 and the voltage waveform 802 is representative of the voltage across the secondary inductor 136. Voltage waveform 801 is representative of the voltage across the primary winding 132 of the transformer 133. The steady state output voltage of the converter at the output leads 161 and 162 may be readily ascertained by equating the volt seconds across the two inductances during the opposite phases of operation.
A self synchronous rectifier 150 (shown in FIG. 1) utilizes the two FETs 151 and 152. The gate of each FET, 151 and 152, is driven by the drain voltage of the other FET, 152 and 151, respectively. These rectifiers regulate from full load to no load without need for a bleeder and without significant changes in duty cycle.
The current flowing in the output capacitor 163, shunting the output leads 161 and 162, equals the sum of the currents flowing in the inductors. The output voltage is given by the expression of equation (7) herein below;
V.sub.out =D*(D-1)*V.sub.in *(N.sub.s /N.sub.p). (7)
While the foregoing converter has been described with respect to an off-line converter normally operating with power factor enhancement circuitry at its input it is to be understood that the principles of the invention may readily be applied to converters operated without power factor correction. It is to be further understood that the principles of the invention apply equally well to other bridge topologies in addition to the half bridge circuit of the illustrative embodiment. Examples are the full bridge topology and other variations of the half bridge topology. | A drive arrangement and operative scheme for the power switching transistors of a half-bridge power drives the two power switching transistors with unequal duty cycles having conducting durations such that the sum of the conduction intervals substantially equals the combined switching period of the two power switching transistors. The conducting intervals are separated by very short dead time intervals controlled by the differing turn-on and turn-off times of the two power switching transistors. The short interval between alternate conductions of the two power switching transistors is sufficient to allow zero voltage turn on of the power switching transistors but short enough to minimize power loss and conducted noise.
Special biasing is provided to prevent drive signal application to power switches prior to attainment of a minimum voltage across the switch.
Circuitry is provided for cancellation of output ripple currents at selected operating points of the power converter. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from Japanese Patent Application No. 2008-327309, filed on Dec. 24, 2008, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a coaxial connector.
DESCRIPTION OF THE RELATED ART
[0003] Japanese Utility Model Application Laid-open No. 60-123666 discloses a coaxial movable contact terminal 851 , as shown in FIG. 19 , which is used in an inspection apparatus. The coaxial movable contact terminal 851 includes a center conductor 852 and an outer conductor 861 having a plain cylindrical shape and surrounding the center conductor 852 . As shown in FIG. 20 , the terminals 851 are held by a movable plate 802 movable relative to a target circuit board 801 on which ICs (Integrated Circuits) are mounted as targets of measurement. Further, coaxial connectors (hereinafter referred to as “coaxial plugs”) 961 are connected to one ends of the terminals 851 , respectively. Each of the coaxial plugs 961 is connected via a coaxial cable 962 to a measuring circuit board (not shown) on which a signal generator circuit, a comparator, etc. are mounted. At the time of the measurement, the movable plate 802 is moved toward the target circuit board 801 to bring the other ends of the terminals 851 into contact with the target circuit board 801 . Consequently, the coaxial plugs 961 are electrically connected to the target circuit board 801 by the terminals 851 , to thereby electrically connect the target circuit board 801 and the measuring circuit board to each other.
[0004] By using the coaxial terminals 851 , a high-frequency component of a signal is hardly attenuated or reflected in the terminals. Accordingly, an input signal outputted by the signal generator circuit in the measuring circuit board is transmitted or transferred to the target circuit board 801 via the terminals 851 as maintaining its waveform satisfactorily. Further, an output signal outputted by an IC as the target of the measurement (measurement target) in the target circuit board 801 is transmitted to the measuring circuit board via the terminals 851 while maintaining its waveform satisfactorily.
[0005] However, the coaxial movable contact terminals 851 of Japanese Utility Model Application Laid-open No. 60-123666 are press-fit in cavities 814 formed in the movable plate 802 ; and the movable plate 802 is moved toward the target circuit board 801 to thereby move the coaxial movable contact terminals 851 upwardly and downwardly so that the terminals 851 are brought into contact with the target circuit board 801 . As described above, the coaxial movable contact terminals 851 are merely in pressure contact with the target circuit board 801 from below. Therefore, for example, in a case that oxide film, etc. is formed on a surface of a land of the target circuit board 801 , there is a fear that the connection resistance is increased due to the oxide film, which in turn creates a possibility that high-frequency signals cannot be received in a desired waveform via the coaxial movable contact terminals 851 .
[0006] Japanese Patent Application Laid-open No. 7-272810 discloses a movable contact pin device for an IC socket. An IC package is mounted on the movable contact pin device. At the time of the mounting, a contact member, of the movable contact pin device, which construct the movable contact pin device is brought into pressurized contact with a connection terminal of the IC package, and then the contact member is rotated by another twisted member constructing the movable contact pin device. In such a manner, the contact member is rotated in a state that the contact member is in contact with the connection terminal to thereby perform wiping. By doing so, it is possible to rub off or remove the oxide film, etc. from the surfaces of the connection terminal and the contact member, making it possible to suppress the increase in connection resistance.
[0007] In the contact rotation mechanism of Japanese Patent Application Laid-open No. 7-272810, however, the contact member is rotated by using the another twisted constructing member which constructs the movable contact pin device. Therefore, it is necessary to arrange the another twisted constructing member at the position of the rotation axis of the contact member. Therefore, in a case that an attempt is made to rotate the outer conductor 861 in the coaxial movable contact terminal 851 disclosed in Japanese Utility Model Application Laid-open No. 60-123666, it is necessary to arrange the another twisted constructing member at a position of the rotation axis of the outer conductor 861 . In the coaxial movable contact terminal 851 , however, the center conductor 852 needs to be arranged at the center of the outer conductor 861 . Thus, in the coaxial movable contact terminal 851 disclosed in Japanese Utility Model Application Laid-open No. 60-123666, even if the attempt were made to arrange the another twisted constructing member, disclosed in Japanese Patent Application Laid-open No. 7-272810, at the position of the rotation axis of the outer conductor 861 , it is not possible to arrange the another twisted constructing member disclosed in Japanese Patent Application Laid-open No. 7-272810 at the position of the rotation axis since the center conductor 852 is already arranged at the position. As a result, in the coaxial movable contact terminal 851 , it is not possible to rotate the outer conductor 861 by using the another twisted constructing member in order to perform the wiping, and thus it is not possible to suppress the increase in connection resistance in the coaxial movable contact terminal 851 .
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a coaxial connector capable of perform wiping in a terminal having coaxial structure such as a probe.
[0009] According to the present invention, there is provided a coaxial connector 1 which is attached to a circuit board 2 having a land 151 , the coaxial connector 1 including: a coaxial terminal 51 which has a coaxial structure including a center terminal 52 and a cylindrical outer terminal 61 surrounding the center terminal 52 ; a housing 11 which accommodates the coaxial terminal 51 ; a cylindrical contact 81 which is movable in an axial direction of an axis of the outer terminal 61 and which is brought into contact with the land 151 ; a biasing member 71 which biases the cylindrical contact 81 so that the cylindrical contact 81 projects from the housing 11 ; and a rotation mechanism which rotates the cylindrical contact 81 about the axis when the cylindrical contact 81 is pushed into the housing 11 against a biasing force of the biasing member 71 . In the present application, the term “land” means a contact point, which is provided on the circuit board, at which the connector is brought into contact with the circuit board and which has any shape. The land may include, for example, a pad, etc.
[0010] Since the cylindrical contact 81 is biased in such a manner by the biasing member so as to project from the housing 11 , the cylindrical contact 81 is first brought into contact with the land 151 of the circuit board 2 when the coaxial connector 1 is attached to the circuit board 2 . Afterwards, the cylindrical contact 81 is pushed or pressed into the housing 11 , whereby the coaxial connector 1 is attached to the circuit board 2 . Then, during a period of time until the coaxial connector 1 is attached to the circuit board 2 , the cylindrical contact 81 brought into contact with the land 151 of the circuit board 2 is rotated about or with respect to the axis by the rotation mechanism.
[0011] Accordingly, since the cylindrical contact 81 is rotated in a state that the cylindrical contact 81 is in contact with the land 151 of the circuit board 2 , it is possible to rub the cylindrical contact 81 and the land 151 against each other to thereby wiping the cylindrical contact 81 and the land 151 . Further, with this wiping, it is possible to rub off or remove an oxide film from a contact portion, of the cylindrical contact 81 , which is brought into contact with the land 151 and the surface of the land 151 of the circuit board 2 and to remove dust or dirt which has been caught between the cylindrical contact 81 and the land 151 , thereby making it possible to suppress the increase in contact resistance between the outer terminal 61 and the circuit board 2 . In the present application, it is possible to perform the wiping in such a manner in the terminal having the coaxial structure.
[0012] Further, the biasing member makes the biasing force constantly act on the cylindrical contact 81 so that the cylindrical contact 81 projects from the housing 11 . Therefore, the cylindrical contact 81 rotates (is rotated) in a state that the cylindrical contact 81 is in pressure contact with the land 151 due to the biasing force. Therefore, even when the housing 11 is strongly pressed against the circuit board 2 , the cylindrical contact 81 is not brought into pressure contact against the land 151 with a force which is greater than the biasing force, thereby making it possible to prevent any damage of the cylindrical contact 81 and/or the land 151 which would be otherwise caused if the cylindrical contact 81 were brought into pressure contact against the circuit board with an excessively strong force. In addition, the biasing member continuously makes the cylindrical contact 81 brought into pressure contact with the land 151 even after the coaxial connector 1 is attached to the circuit board 2 . Therefore, it is possible to maintain a state that the contact resistance is lowered between the cylindrical contact 81 and the land 151 .
[0013] The biasing member may be a member which is elastically deformable such as, for example, a coil spring, a leaf spring or the like. In a case that the biasing member is a coil spring 71 which is arranged coaxially with the coaxial terminal 51 , the rotation mechanism which rotates the cylindrical contact 81 may include a projection 84 which is formed in the cylindrical contact 81 and with which one end of the coil spring 71 is brought into contact; and the cylindrical contact 81 may be rotated when the coil spring 71 is expanded or compressed to pull or push the projection 84 .
[0014] In such a manner, by expanding or compressing the coil spring 71 to thereby pull or push the projection 84 formed in the cylindrical contact 81 , it is possible to use the coil spring 71 as the biasing member also in the rotation mechanism rotating the cylindrical contact 81 . This makes it possible to reduce the number of components or parts arranged around the coaxial terminal 51 and to simplify the structure of the terminal. In addition, the coil spring 71 can be arranged coaxially with the coaxial terminal 51 in a state that, for example, the coil spring 71 is wound around the outer terminal 61 . As a result, it is possible to reduce an area or range occupied by each of the coaxial terminals 51 in the housing 11 , thereby making it possible to arrange, in the housing 11 , a plurality of pieces of the coaxial terminal 51 at a pitch that is same as that of conventional coaxial terminals which is not provided with the coil spring 71 , etc.
[0015] Further, in the present invention, the coil spring 71 may be brought into contact with the projection 84 in a state that the coil spring 71 is compressed. By bringing the coil spring 71 in the compressed state into contact with the projection 84 , it is possible to push and rotate the cylindrical contact 81 in assured manner. Further, when the cylindrical contact 81 is pushed into the housing 11 to further compress the coil spring 71 , the force pushing (pressing) the cylindrical contact 81 becomes greater, thereby making it possible to rotate the cylindrical contact 81 assuredly even if the cylindrical contact 81 is hooked to or caught by the land 151 . On the other hand, in a case that the projection 84 is pulled by the expanded coil spring 71 , the cylindrical contact 81 is pushed into the housing 11 to thereby suppress the expansion of the coil spring 71 , thus cancelling the force pulling the projection 84 .
[0016] Furthermore, in the present invention, the rotating mechanism which rotates the cylindrical contact 81 may further include: a fix portion 26 which is formed in the coaxial terminal 51 or the housing 11 , and a movable portion 85 which is formed in the cylindrical contact 81 and which is engaged with the fix portion 26 ; and the cylindrical contact 81 may start to rotate when the cylindrical contact 81 is pushed into the housing 11 to disengage the movable portion 85 from the fix portion 26 .
[0017] In this manner, when the cylindrical contact 81 is pushed into the housing 11 to thereby disengage the movable portion 85 from the fix portion 26 (release the engagement between the fix portion 26 and the movable portion 85 ), the cylindrical contact 81 starts to rotate. Accordingly, it is possible to prevent the cylindrical contact 81 from rotating when the cylindrical contact 81 is not pushed into the housing 11 , and to make the cylindrical contact 81 rotate when the cylindrical contact 81 is pushed into the housing 11 against the biasing force of the biasing member.
[0018] In particular, in a case that the coil spring 71 as the biasing member is a mechanism which rotates the cylindrical contact 81 when the coil spring 71 is brought into contact with the projection 84 formed in the cylindrical contact 81 , the coil spring 71 is in a compressed state when the cylindrical contact 81 is pushed into the housing 11 to thereby disengage the movable portion 85 from the fix portion 26 . Therefore, when the cylindrical contact 81 starts rotating, the coil spring 71 in the compressed state is brought into contact with the projection 84 . Therefore, even if the cylindrical contact 81 is caught by or hooked to the land 151 before the cylindrical contact 81 starts rotating, it is possible to surely rotate the cylindrical contact 81 by the force releasing the compression of the spring force 71 .
[0019] Moreover, in the present invention, the rotation mechanism may further include a restricting portion 27 which is formed in the coaxial terminal 51 or the housing 11 and which is engaged with the movable portion 85 , disengaged from the fix portion 26 , to restrict movement of the movable portion 85 . By providing, in such a manner, the restricting portion 27 which is engaged with the movable portion 85 disengaged from the fix portion 26 , it is possible to restrict (regulate) a range in which the cylindrical contact 81 is rotated to a range in which the movable portion 85 is moved from the fix portion 26 to the restricting portion 27 . That is, by limiting a rotation amount of the cylindrical contact 81 , it is possible to restrict a range in which the wiping is performed on the land 151 (circuit board 2 ).
[0020] Further, in the present invention, the cylindrical contact 81 may have a plurality of projecting contact points 83 which are arranged on the cylindrical contact 81 at rotationally symmetric positions of a cylindrical shape of the cylindrical contact to project from the cylindrical contact and which are brought into contact with the land 151 .
[0000] In this case, it is possible to bring the cylindrical contact 81 into contact with the land 151 at the plurality of projecting contact points 83 in assured manner, and to wipe the land 151 assuredly. Further, it is enough that the land 151 is formed on the circuit board 2 at a range in which the plurality of projecting contact points 83 perform the wiping (range in which the plurality of projecting contact points 83 are brought into contact with the land 151 ). On the other hand, in a case that the plurality of projecting contact points 83 is not provided, the contact range on the circuit board 2 which is brought into contact with the cylindrical contact 81 cannot be determined, which in turn necessitate forming, for example, a doughnut-shaped land corresponding to the cylindrical shape of the cylindrical contact 81 , or creating possibility such that the cylindrical contact 81 erroneously wipes a portion, of the circuit board 2 , which is different from the land 151 .
[0021] As described above, in the coaxial connector of the present invention, it is possible to perform the wiping in the terminal having the coaxial structure such as a probe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a connector of an embodiment of the present invention and a circuit board;
[0023] FIG. 2 is a partial exploded perspective view of the connector shown in FIG. 1 ;
[0024] FIG. 3 is a partial exploded perspective view of a housing and a coaxial terminal in FIG. 2 ;
[0025] FIG. 4 is a partial exploded perspective view of a portion of the coaxial terminal shown in FIG. 3 ;
[0026] FIG. 5 is a view showing a partial assembly state of the connector shown in FIG. 1 , with a partial cutout;
[0027] FIG. 6 is a partial view showing further partial assembly state of the connector shown in FIG. 1 , with a partial cutout;
[0028] FIG. 7 is a partial view showing still further partial assembly state of the connector shown in FIG. 1 , with a partial cutout;
[0029] FIG. 8 is a partial view showing further assembly state of the connector shown in FIG. 1 , with a partial cutout;
[0030] FIGS. 9A to 9D are explanatory views each showing a state when the connector shown in FIG. 1 is attached to the circuit board;
[0031] FIG. 10 is a partial perspective view of the connector corresponding to FIG. 9A , with partial cutout;
[0032] FIG. 11 is a partial perspective view of the connector corresponding to FIG. 9B , with partial cutout;
[0033] FIG. 12 is a partial perspective view of the connector corresponding to FIG. 9C , with partial cutout;
[0034] FIG. 13 is a partial perspective view of the connector corresponding to FIG. 9D , with partial cutout;
[0035] FIG. 14 is a partial bottom view of the connector in the state shown in FIG. 9A ;
[0036] FIG. 15 is a partial bottom view of the connector in the state shown in FIG. 9C ;
[0037] FIG. 16 is a perspective view of a holder which is to be connected to the connector in FIG. 1 ;
[0038] FIG. 17 is a vertical sectional view showing a state that the holder in FIG. 16 is connected to the connector in the state shown in FIG. 9D ;
[0039] FIG. 18 is a partial exploded perspective view of a housing and a coaxial terminal of a connector of a modification of the present invention;
[0040] FIG. 19 is a cross-sectional view showing a conventional coaxial movable contact terminal; and
[0041] FIG. 20 is a view showing the coaxial movable contact terminal shown in FIG. 19 is in use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] In the following, an explanation will be given about an embodiment of a coaxial connector of the present invention with reference to the drawings. It should be noted that the embodiment described below is an example of a preferred embodiment of the present invention and is not intended to limit the present invention.
[0043] FIG. 1 is a perspective view of a connector 1 of the embodiment seen from obliquely above. FIG. 1 also shows a circuit board 2 to which the connector 1 is to be attached. The connector 1 has a housing 11 which is formed in a cubic shape by using an insulating material such as resin; a plurality of cavities 14 which penetrate through the housing 11 in an up and down direction; and a plurality of coaxial terminals 51 each of which has a coaxial structure including a center terminal 52 and an outer terminal 61 and which are accommodated in the cavities 14 , respectively.
[0044] As shown in FIG. 1 , a plurality of lands 151 are formed in the circuit board 2 . Electric wirings such as through holes (not shown) are connected to the lands 151 .
[0045] As shown in FIGS. 9D and 17 (which will be described later), the connector 1 is attached to the circuit board 2 at a lower surface 12 a of the housing 11 . Further, in each of the coaxial terminals 51 , the center terminal 52 and the outer terminal 61 which project downward from the housing 11 are brought into contact with and electrically connected to three pieces of the land 151 , the lands 151 being aligned on the circuit board 2 such that land rows are each formed of three pieces of the land 151 .
[0046] FIG. 2 is an exploded perspective view of the housing 11 . The housing 11 is vertically divided into two parts by a plane extending in parallel to the circuit board 2 and thereby includes a lower housing 12 and an upper housing 13 . The lower housing 12 is positioned under the upper housing 13 in FIG. 1 and is directly attached to the circuit board 2 ; and a lower surface 23 of the upper housing 13 and an upper surface 22 of the lower housing 12 are in contact with each other. Further, the plurality of cavities 14 are formed in the housing 11 . Each of the cavities 14 is constructed of a lower cavity 24 formed in the lower housing 12 and an upper cavity 25 formed in the upper housing 13 .
[0047] Furthermore, in the lower housing 12 , two pieces of an anchor press-fit slit 19 and two pieces of a movable piece-slit 28 are formed to communicate with each of the lower cavities 24 . Moreover, as shown in FIG. 5 (which will be described later), a lower end portion of each of the movable piece-slits 28 functions as a restricting recess portion 27 ; and a fix recess portion 26 a is defined by a groove extending downwardly from the restricting recess portion 27 . The two anchor press-fit slits 19 the two movable piece-slits 28 are both formed in the lower housing 12 such that the two anchor press-fit slits 19 are arranged to be rotationally symmetric with respect to the lower cavity 24 having columnar shape (that is, arranged at an interval of 180 degrees), and that the two movable piece-slits 28 are arranged to be rotationally symmetric with respect to the lower cavity 24 having columnar shape (that is, arranged at an interval of 180 degrees).
[0048] FIGS. 3 and 4 are each an exploded view of the coaxial terminal 51 which is accommodated in the cavity 14 .
[0049] Each of the coaxial terminals 51 includes the center terminal 52 , the outer terminal 61 , and an insulator 41 via which the outer terminal 61 holds the center terminal 52 in an insulated state; and each of the coaxial terminals 51 is accommodated in one of the cavities 14 formed in the housing 11 as shown in FIG. 2 . The center terminal 52 is mated with an axial terminal 162 of a coaxial plug 161 as shown in FIG. 16 (to be described later); and the outer terminal 61 is mated with a surrounding terminal 163 of the coaxial plug 161 .
[0050] As shown in FIG. 4 , the center terminal 52 includes a center conductor 53 , a center coil spring (not shown), and a shaft-shaped contact 59 each of which is formed by using a conductive material. The center conductor 53 has a substantially shaft shape and has, on the upper portion thereof, a mating portion 55 holding or sandwiching the axial terminal 162 of the coaxial plug 161 . Further, a center hole 56 is formed in the lower surface of the center conductor 53 having the shaft shape; and the center coil spring and one end of the shaft-shaped contact 59 are inserted in the center hole 56 .
[0051] As shown in FIG. 4 , the insulator 41 has a cylindrical shape and includes a large-diameter portion and a small-diameter portion which are coaxial. A center hole 42 is formed at the center of the cylindrical insulator 41 , and the center terminal 52 is inserted in the center hole 42 .
[0052] As shown in FIGS. 3 and 4 , the outer terminal 61 includes an outer conductor 62 , an outer coil spring 71 and a cylindrical contact 81 each of which is formed by using a conductive material such as a metal plate. The outer conductor 62 has a substantially cylindrical shape as a whole and includes a body portion 64 having a pair of anchors 63 projecting or protruding from the surface (outer surface) of the body portion 64 ; a mating portion 66 formed above the body portion 64 ; and a thin cylinder portion 67 which is formed below the body portion 64 . The mating portion 66 is constructed of four leaf springs 65 which hold the surrounding terminal 163 of the coaxial plug 161 . The thin cylinder portion 67 is formed to be thinner than the body portion 64 and is inserted in the outer coil spring 71 and the cylindrical contact 81 .
[0053] As shown in FIG. 3 , the cylindrical contact 81 is formed to have a cylindrical shape into which the thin cylinder portion 67 can be inserted and is movable in the axial direction of the outer terminal 61 . Further, a projection 84 , two movable pieces 85 , and two projecting contact points 83 are formed in the cylindrical contact 81 . The projection 84 projects from an upper edge portion of the cylinder of the cylindrical contact 81 such that a stepped shaped-portion is formed on the upper edge portion of the cylindrical shape of the cylindrical contact 81 . Each of the movable pieces 85 projects from the outer surface of the upper portion of the cylindrical contact 81 having the cylindrical shape. Each of the projecting contact points 83 projects from the lower end of the cylindrical contact 81 having the cylindrical shape. Note that the two movable pieces 85 and the two projecting contact points 83 are both formed on the outer surface of the cylindrical contact 81 having the cylindrical shape, such that the two movable pieces 85 are arranged to be rotationally symmetric with respect to each other (that is, arranged at an interval of 180 degrees) and that the two projecting contact points 83 are arranged to be rotationally symmetric with respect to each other (that is, arranged at an interval of 180 degrees).
[0054] Upon assembling the coaxial terminal 51 , the center terminal 52 is first inserted in the center hole 42 of the insulator 41 , and then the insulator 41 is inserted in the outer conductor 62 , whereby the center terminal 52 and the insulator 41 are assembled in the outer conductor 62 as shown in FIG. 3 . In the following explanation, the outer terminal 62 , in which the insulator 41 and the center terminal 52 are assembled, is referred to as “sub-assembly”.
[0055] Next, assembly processes of the connector 1 as shown in FIG. 1 will be explained with reference to FIGS. 5 to 8 . First, as shown in FIG. 5 , the cylindrical contact 81 is inserted in the lower cavity 24 . At this time, the movable pieces 85 of the cylindrical contact 81 are inserted in the movable piece-slits 28 of the lower housing 12 , respectively. With this, the movable pieces 85 are accommodated in the fix recess portions 26 each forming the lower end portion of one of the movable piece-slits 28 .
[0056] Next, as shown in FIG. 6 , the outer coil spring 71 is inserted in the lower cavity 24 . With this, the outer coil spring 71 is disposed above the cylindrical contact 81 in the lower cavity 24 . Further, a lower end of the winding forming the outer coil spring 71 is capable of abutting on the projection 84 of the cylindrical contact 81 .
[0057] Next, as shown in FIG. 7 , the sub-assembly is inserted in the lower cavity 24 . At this time, the pair of anchors 63 are press-fit in the pair of anchor press-fit slits 19 formed in the lower housing 12 . With this, the sub-assembly is fixed to the lower housing 12 . Further, the center terminal 52 and the outer terminal 61 of the coaxial terminal 51 are coaxially structured.
[0058] In the state that the pair of anchors 63 are press-fit in the anchor press-fit slits 19 , the outer coil spring 71 is sandwiched between the outer conductor 62 and the cylindrical contact 81 to be compressed. Therefore, the lower end of the winding of the outer coil spring 71 is pressed against the projection 84 of the cylindrical contact 81 ; and the other end, of the winding, which is the upper end of the coil spring 71 is pressed against a fix piece 69 of the outer conductor 62 . Note that a pressed state same as that described above may be provided by inserting the sub-assembly in the lower cavity 24 while twisting the sub-assembly.
[0059] Since the outer conductor 62 is in a state that the pair of anchors 63 are press-fit in the anchor press-fit slits 19 to thereby prevent the outer conductor 62 from rotating in the lower cavity 24 (cavity 14 ), the compressed outer coil spring 71 presses or pushes the projection 84 of the cylindrical contact 81 and thus the movable pieces 85 inserted in the fix recess portions 26 are positioned in the fix recess portions 26 .
[0060] Afterwards, as shown in FIG. 8 , the upper housing 13 is stacked or placed on the lower housing 12 . With this, the coaxial terminal 51 is accommodated in the cavity 14 constructed of the upper cavity 25 and the lower cavity 24 , thereby completing the assembly of the connector 1 as shown in FIG. 1 . At this time, the outer conductor 62 and the cylindrical contact 81 are always electrically connected by the outer coil spring 71 which is in pressurized contact with the outer conductor 62 and the cylindrical contact 81 .
[0061] Further, in the state that the coaxial terminal 51 is accommodated in the cavity 14 , the lower end of the cylindrical contact 81 projects from the lower surface 12 a of the lower housing 12 due to the downward biasing force of the outer coil spring 71 . The two projecting contact points 83 , of the cylindrical contact 81 projecting from the lower surface 12 a of the lower housing 12 , are brought into contact with the lands 151 of the circuit board 2 shown in FIG. 1 . The cylindrical contact 81 is movable in the axial direction of the thin cylinder portion 67 (outer terminal 61 ), and by this movement of the cylindrical contact 81 , a projection amount by which the cylindrical contact 81 projects from the lower surface 12 a of the lower housing 12 can be changed or made variable. Similarly, the lower end of the shaft-shaped contact 59 also projects from the lower surface 12 a of the lower housing 12 , due to the downward biasing force of the center coil spring. The shaft-shaped contact 59 projecting from the lower housing 12 is brought into contact with the land 151 of the circuit board 2 shown in FIG. 1 . Further, the shaft-shaped contact 59 is also movable in the axial direction of the center terminal 52 ; and by this movement of the shaft-shaped contact 59 , a projection amount by which the shaft-shaped contact 59 projects from the lower surface 12 a of the lower housing 12 can be changed or made variable.
[0062] Next, an explanation will be given about a method of attaching the connector 1 shown in FIG. 1 to the circuit board 2 , with reference to FIGS. 9 to 15 . Note that the states shown in FIGS. 10 to 13 respectively are in one-to-one correspondence to the states shown in FIGS. 9A to 9D . Further, the bottom view shown in FIG. 14 corresponds to the state shown in FIG. 9A and the bottom view shown in FIG. 15 corresponds to the state shown in FIG. 9C .
[0063] First, as shown in FIG. 9A , the pair of projecting contact points 83 of the cylindrical contact 81 and the shaft-shaped contact 59 are brought into contact with the lands 151 of the circuit board 2 . At this time, as shown in FIG. 10 , the movable pieces 85 of the cylindrical contact 81 are engaged with the fix recess portions 26 of the housing 11 .
[0064] Next, the housing 11 is pressed against the circuit board 2 . With this, as shown in FIGS. 9B to 9D , the cylindrical contact 81 and the shaft-shaped contact 59 are pushed into the housing 11 . Then, as shown in FIG. 9D , the bottom surface 12 a of the housing 11 is brought into contact with the circuit board 2 , thereby attaching the connector 1 to the circuit board 2 .
[0065] By pressing the housing 11 against the circuit board 2 in such a manner, the cylindrical contact 81 is pushed into the housing 11 against the biasing force of the outer coil spring 71 while being kept in pressure contact with the lands 151 . Further, the shaft-shaped contact 59 pressed downward by the center coil spring (not shown) is also pushed into the housing 11 against the biasing force of the center coil spring while being kept in pressure contact with the land 151 .
[0066] By pushing the cylindrical contact 81 into the housing 11 in such a manner, the movable pieces 85 inserted in the movable piece-slits 28 move upward in the movable piece-slits 28 as shown in FIGS. 10 to 13 . Specifically, when the movable pieces 85 engaged with the fix recess portions 26 as shown in FIG. 10 start to move upwardly, the movable pieces 85 are disengaged or released from the fixed recess portions as shown in FIG. 11 and the movable pieces 85 are rotated together with the cylindrical contact 81 by the force of the outer coil spring 71 attempting to expand because the outer coil spring 71 is in the compressed state. Then, as shown in FIG. 12 , the movable pieces 85 are engaged with the restricting recess portions 27 ; and as shown in FIG. 13 , the movable pieces 85 move further upwardly in the movable piece-slits 28 while being kept engaged with the restricting recess portions 27 . Note that as shown FIGS. 14 and 15 which are bottom views, the cylindrical contact 81 is rotated clockwise.
[0067] Further, the cylindrical contact 81 is rotated by the force of the outer coil spring 71 during a period of time during which the state shown in FIG. 11 is changed to the state shown in FIG. 12 . Therefore, the projecting contact points 83 are moved on the lands 151 of the circuit board 2 while being kept in contact with the lands 151 as shown in FIGS. 9B and 9C . Further, also during this period, the downward force by the compressed outer coil spring 71 acts on the cylindrical contact 81 . Therefore, the projecting contact points 83 are rubbed against the lands 151 . Consequently, it is possible to rub off or remove an oxide film from the surfaces of the pair of projecting contact points 83 and of the lands 151 and to remove dust or dirt which has been caught between the projecting contact points 83 and the lands 151 .
[0068] FIG. 16 is a perspective view showing a plug 3 which is to be attached to the connector 1 of this embodiment. The plug 3 includes a holder 121 . In the holder 121 , a plurality of cavities 123 are formed in arrangement corresponding to that of the coaxial probes 51 of the connector 1 . In the cavities 123 , the coaxial plugs 161 are inserted respectively. Each of the coaxial plugs 161 includes the axial terminal 162 and the surrounding terminal 163 which surrounds the axial terminal 162 and which is arranged coaxial with the axial terminal 162 .
[0069] FIG. 17 is a view showing a state that the plug 3 is mated with the connector 1 which is attached to the circuit board 2 . In this mated state, each of the coaxial plugs 161 of the plug 3 is mated with one of the coaxial probes 51 of the connector 1 . Specifically, the axial terminal 162 of each of the coaxial plugs 161 is pushed into the mating portion 55 of one of the center conductors 53 . With this, the axial terminal 162 of each of the coaxial plugs 161 is electrically and securely connected to the land 151 of the circuit board 2 via the center terminal 52 . Further, the surrounding terminal 163 of each of the coaxial plugs 161 is inserted into a plurality of leaf springs 65 of the mating portion 55 of one of the outer conductors 62 to thereby push the leaf springs 65 . With this, the surrounding terminal 163 of the coaxial plug 161 is electrically and securely connected to the land 151 of the circuit board 2 via the outer terminal 61 .
[0070] As described above, by pressing the housing 11 in the contact state in FIG. 9A against the circuit board 2 , the cylindrical contacts 81 is rotated while being pushed into the housing 11 as shown in FIGS. 10 to 13 and the connector 1 of this embodiment is attached to the circuit board 2 as shown in FIG. 9D . Therefore, the pair of projecting contact points 83 brought into contact with the lands 151 of the circuit board 2 in FIG. 9A are rotated on the lands 151 to rub against the lands 151 during a period of time during which the state shown in FIG. 9B is changed to the state shown in FIG. 9C . With this, it is possible to perform the wiping of the pair of projecting contact points 83 and the lands 151 .
[0071] As described above, in the connector 1 of this embodiment, it is possible to perform the wiping upon attaching the connector 1 to the circuit board 2 , even though the terminals of the connector 1 are the coaxial terminals 51 . Further, by this wiping, it is possible to rub off or remove the oxide film from the surfaces of the pairs of projecting contact points 83 and the lands 151 and to remove dust caught therebetween, thereby making it possible to prevent the increase in contact resistance between the coaxial terminals 51 and the lands 151 .
[0072] In addition, since each of the cylindrical contacts 81 is brought into pressure contact with the lands 151 by the outer coil spring 71 , it is possible to bring the pairs of projecting contact points 83 into contact with the lands 151 before the housing 11 is attached to the circuit board 2 , to bring the pairs of projecting contact points 83 into pressure contact with the lands 151 by a desired biasing force at the time of the wiping, and to reduce the contact resistance between the pairs of projecting contact points 83 and the lands 151 in the state that the housing 11 is attached to the circuit board 2 .
[0073] Further, the pair of projecting contact points 83 are arranged on the cylindrical contact 81 at rotationally symmetric positions of the cylindrical shape of the cylindrical contact 81 . With this, it is possible to limit or regulate a contact portion, at which the cylindrical contact 81 and the lands 151 are brought into contact with each other, to the pair of projecting contact points 83 and to assuredly bring the cylindrical contact 81 into contact with the lands 151 . Further, it is sufficient that the lands 151 are formed on the circuit board 2 at a range in which the pairs of projecting contact points 83 perform the wiping, thereby eliminating any need to form the land 151 in a doughnut shape or the like corresponding to the cylindrical shape of the cylindrical contact 81 . Furthermore, it is possible to prevent the cylindrical contacts 81 from erroneously wiping portions other than the lands 151 of the circuit board 2 .
[0074] Since the terminals of the connector 1 are the coaxial terminals 51 , it is possible to prevent crosstalk among the plurality of coaxial terminals 51 . As a result, in the connector 1 , it is possible to obtain the performance sufficient for transmitting or transferring high-frequency component of the signal. Accordingly, the connector 1 can be used, in an IC inspection apparatus or the like, for connecting a target circuit board having an IC as the measurement target mounted thereon to a measuring circuit board having a signal generator circuit, a comparator, etc. mounted thereon, with the coaxial cables and without any soldering.
[0075] Note that in this embodiment, although the pair of projecting contact points 83 are formed in each of the cylindrical contacts 81 , it is allowable that the number of the projecting contact points 83 is one or not less than three. In a case that the plurality of projecting contact points 83 are formed in the cylindrical contact 81 , the plurality of projecting contact points 83 may be provided on the cylindrical contact 81 having the cylindrical shape, in arrangement other than the rotational symmetry.
[0076] Further, in this embodiment, the projection 84 of the cylindrical contact 81 is pushed by the compressed outer coil spring 71 . However, the cylindrical contact 81 may be rotated by pulling the projection 84 by the expanded outer coil spring 71 .
[0077] Further, in this embodiment, the fix recess portions 26 and the restricting recess portions 27 which are engaged with the movable pieces 85 of the cylindrical contact 81 are formed in the housing 11 . However, at least either one of the fix recess portions 26 and the restricting recess portions 27 may be formed in the coaxial terminal 51 at a portion which is different from the cylindrical contact 81 (for example, at the outer conductor 62 or the like). Further, at least one of the fix recess portion 26 and the restricting recess portion 27 may be a fix projection.
[0078] FIG. 18 shows a partial exploded perspective view of a connector 1 according to a modification of the present invention. The connector 1 includes an outer terminal 61 which has an outer conductor 62 , an outer coil spring 71 , a cylindrical contact 81 , and a cover 225 . The cover 225 has a cylindrical shape of which inside diameter is greater than the outside diameter of each of the spring 71 and the cylindrical contact 81 , and the cover 225 can accommodate, in an assembled state, the spring 71 and an upper portion of the cylindrical contact 81 inside the cover 225 . Further, the cover 225 is arranged so that a slit 228 , which is formed in the cover 225 at the upper edge of the cylindrical shape of the cover 225 , is engaged with a fix piece, thereby preventing the cover 225 from rotating. Furthermore, the cover 225 is provided with fix recess portions 226 and restricting recess portions 227 which are formed in the cover 225 at the lower edge of the cylindrical shape of the cover 225 , and which accommodate movable pieces 85 of the cylindrical contact 81 therein. With this structure, in a state that the cylindrical contact 81 projects from a lower surface 12 a of a housing 11 , the movable pieces 85 abut on the fix recess portions 226 and thus the cylindrical contact 81 does not rotate. Upon attaching the connector 1 to the circuit board 2 , the cylindrical contact 81 is pushed into the housing 11 , which results in the movable pieces 85 moving from the fix recess portions 226 to the restricting recess portions 227 , thereby rotating the cylindrical contact 81 by the spring force of the outer coil spring 71 .
[0079] Further, in this embodiment, the outer coil spring 71 is used to generate the force which acts on the cylindrical contact 81 such that the cylindrical contact 81 is projected from the housing 11 . Alternatively, for example, the biasing force may be generated by using a leaf spring or the like to act on the cylindrical contact 81 . Furthermore, the leaf spring may be formed as a leaf spring structure as a part of the housing 11 .
[0080] The coaxial connector of the present invention can perform the wiping by rotating the cylindrical contacts brought into contact with the lands of the circuit board, upon attaching the coaxial connector to the circuit board. Therefore, it is possible to electrically connect the cylindrical contacts and the lands of the circuit board with a low contact resistance. Accordingly, the coaxial connector of the present invention can be used, for example in an IC inspection apparatus, etc., for connecting a target circuit board having an IC as the measurement target mounted thereon to a measuring circuit board having a signal generator circuit, a comparator, etc. mounted thereon, with the coaxial cable. | A coaxial connector ( 1 ), which is attached to a circuit board ( 2 ) having a land ( 151 ), includes a coaxial terminal ( 51 ) having a coaxial structure including a centre terminal ( 52 ) and a cylindrical outer terminal ( 61 ) surrounding the centre terminal; a housing ( 11 ) accommodating the coaxial terminal; a cylindrical contact ( 81 ) movable in an axial direction of an axis of the outer terminal and brought into contact with the land; a biasing member ( 71 ) biasing the cylindrical contact so that the cylindrical contact projects from the housing; and a rotation mechanism which rotates the cylindrical contact about the axis when the cylindrical contact is pushed into the housing against a biasing force of the biasing member. Accordingly, the coaxial connector capable of performing wiping in a terminal having the coaxial structure, such as a probe, is provided. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to non-volatile semiconductor memory chips, and more particularly, relates to an electrically operated, resistive memory element including a volume of resistive memory material, such as a phase change material.
BACKGROUND
[0002] Optically rewritable disks, such as compact disks (CDs) or digital versatile disks (DVDs), typically use phase change materials for storing information, which, using a laser beam, are switched between their crystalline and amorphous states. Since the optical reflectivity of the phase change material differs in its crystalline and amorphous states, a change of phase can be used to store and read digital information.
[0003] As has been found, amorphous and crystalline states not only differ in their optical reflectivities, but also in their electric resistivity values, so that a particular state can also be read electrically. This is the reason why resistive memory cells based on phase change materials may represent a new type of non-volatile memory cells that could replace the dynamic random access memory (DRAM) as the standard memory for computing devices. Particularly, the use of phase change memory devices as a non-volatile RAM will eventually allow for “instant on” systems that come to life as soon as the computer system is turned on, thus saving the amount of time needed for a conventional computer to transfer boot data from a hard disk drive to volatile DRAM during system power up.
[0004] Specific alloys having at least one element of group VI of the periodic table of elements, such as Te or Se, also referred to as chalcogenides, may be used in resistive memory cell applications, since the electric resistivity has been found to vary by at least two order of magnitudes when such alloy is switched between the more resistive amorphous phase and the less resistive crystalline phase.
[0005] An amorphous-crystalline phase transition of the phase change material is induced by raising the temperature above crystallization temperature of the material, so that a fast nucleation of crystallites can take place. Such transition starting from the amorphous phase and arriving at the crystalline phase typically is referred to as “writing” a memory cell. To bring the phase change material back to its amorphous state, it is necessary to raise the temperature above the melting temperature of the material and then cool off rapidly. Such transition starting from the crystalline phase and arriving at the amorphous phase typically is referred to as “erasing” a memory cell. Both crystallization and melting temperatures can, for instance, be reached by causing a current to flow through a resistive element, which heats the phase change material by the Joule effect.
[0006] For electrically reading the state of a memory cell using a phase change material, a reading voltage is applied to the cell, with the proviso that the reading current resulting therefrom must be smaller than the currents for writing or erasing in order to not effect an inadvertent writing or erasing of the memory cell.
[0007] However, a considerable drawback of such phase change memory cells is seen in the relatively high writing and erasing currents, which must be applied to a selected memory cell to raise the temperature of the phase change material above the crystallization and melting temperatures. In order to successfully integrate such phase change memory cells into convenient silicon CMOS processing the following has to be observed: if the electric currents, which are applied for reading or erasing a phase change memory cell, are too big to be supplied by a single CMOS tranistor having a minimum structure size, there is no possibility to realize a compact memory cell array comprising single memory cells in a 1 transistor/1 resistor-arrangement having a cell size of not more than 5-8 F 2 (where F is the minimum feature size of the technology used for fabrication) is not possible. If the above precondition is met, at present, a maximum electric current ranging from 50 to 100 μA (dependent from the actual structure size) can be supplied by a single transistor. Accordingly, a further reduction of writing and erasing currents of the phase change memory cells is highly advantageous, since energy consumed by the memory device can be lowered and parallel programming of the phase change memory cells can be enabled.
[0008] So far, in efforts to reduce writing and erasing currents, developers have attempted to diminish the programmable volume of the phase change material by reducing a contact area between the heating electrode and the phase change material, since currents necessary for writing or erasing typically scale with the programmable volume of the phase change material. Such known undertakings, however, are limited by the minimum (photo-)lithographic dimensions which can be reached, which at present typically amount to about 100 nm. Furthermore, doping of the phase change material using doping materials, such as nitrogen in order to enhance the speficic resistivity to gain a reduction in heating currents, is also known. However, because of physical limitations, not more than about 10% nitrogen can be introduced into the phase change material, and, in doping the phase change material other material parameters, such as crystallization temperature, crystallization speed, grain size and the like, are likely to be changed which may result in undesired effects.
[0009] A resistive memory element which further reduces heating currents, i.e., writing or erasing currents, of the resistive memory material, such as a phase change material, without being bound to physical size limitations of the technology used for fabrication or having adverse effects on material parameters of the resistive memory material is desirable.
SUMMARY
[0010] An electrically operated, resistive memory element for use in a resistive memory cell, has a volume of resistive memory material, that is adapted to be switched between different detectable resistive states in response to selected enery pulses applied thereto. Throughout this specification, the terms “resistive memory element” and “resistive memory material,” respectively, are used to describe resistive memory cells and resistive memory materials, respectively, of any kind, which can be brought into two or more states exhibiting different electrical resistance values, such as phase change materials. The resistive memory element further includes a means for delivering electrical signals to at least a portion of the volume of the resistive memory material, which may be, for example, first and second electrical contacts, which adjoin the resistive memory material. The resistive memory element also includes a volume of heating material for Ohmic heating of the resistive memory material in response to the electrical signals being supplied by the first and second electrical contacts. The heating material is embedded (integrated) in the volume of resistive memory material. The heating material, for instance, is selected to have a specific electrical resistivity value relatively greater than that one of the resistive memory material in its lowest resistance state so that it can effectively be used for heating of the resistive memory material. The specific electric resistivity of the heating material may be chosen to meet specific requirements and typically can be varied within a broad range of possible specific electric resistivity values. In the case where the natural specific resistivity of the resistive memory material is very low (e.g., <5 mΩcm), this choice is required to enable low current memory operation.
[0011] Integrating (embedding) the heating material into the resistive memory material allows the total electric resistivity of the active material formed by the volume of resistive memory material and the volume of heating material embedded therein to be adjusted, without adverse effects on other material characteristices of the active material, such as its crystallization behavior. Enhancing the operating voltage of the resistive memory cell having the resistive memory element, for instance, from 0.3 Volts to 1 Volt, the currents necessary for heating the resistive memory material above critic temperatures of the resistive memory material in writing or erasing the resistive memory cell can be reduced. In general, a trade-off between enhancing the operating voltage and reducing the heating currents for writing or erasing the memory cell may be attained. Furthermore, embedding the heating material into the resistive memory material can minimize the thermal losses due to thermal conductivity.
[0012] In a first embodiment of the invention, one of the first and second electrical contacts providing a means for supplying electric signals is chosen to be a heater electrode for heating the resistive memory material using the Joule effect. The term “heater electrode” as used in the present invention describes an electrode with relatively smaller contact dimension than the counter electrode in order to locally increase the current density in the resistive memory material. In that embodiment, the resistive memory element may also include a layer made of the resistive memory material sandwiched between the heater electrode and the volume of resistive memory material.
[0013] In a second embodiment of the invention, one of the first and second electrical contacts is a plug electrode adapted to be connected to a transistor device. In the second embodiment, a via opening can be provided between the plug and the other one of the first and second electrical contacts, where the via opening is partly or completely filled with the resistive memory material, which is contacting the plug.
[0014] According to the invention, the volume of heating material forms at least one heating material layer, and, together with the resistive memory material may, for example, be arranged in a stacked overlying relationship. The at least one layer made of heating material, for instance, has a thickness in the range of 2 to 70 nanometers, and, more specifically, lies in the range of 5 to 20 nanometers. Particularly, using a heating material having a relatively high specific resistivity and, for instance, relatively low specific thermal capacity, the heating layer may be a very thin layer which, for instance, may have a thickness as thin as 5 nanometers. Accordingly, since the heating layer has a very low thermal capacity, relatively little additional thermal energy for heating the heating layer itself is supplied.
[0015] In the first embodiment of the invention, a distance between the heating material layer and the heater electrode under certain circumstances, for example, is chosen to be relatively greater than a distance between the heating material layer and the other one of the first and second electrical contacts.
[0016] Otherwise, in the second embodiment of the invention, a distance between the heating material layer and the electrical contact, for instance, is chosen to be relatively greater than a distance between the heating material layer and the plug.
[0017] According to the invention, the heating material is selected, for example, to have a thermal conductivity being relativley greater than that one of the resistive memory material. In that case, an improved homogeneous lateral distribution of temperature across the memory element may be achieved. Since local over-heating can be avoided by that measure, life-time of the memory cell can be enhanced, and, positive effects on the reading signal may also be observed.
[0018] In the resistive memory element according to the invention, the resistive memory material, for instance, is chosen to be a phase change material. In one embodiment, the phase change material includes, for instance, at least one chalcogen element, and may, for instance, be Ge 2 Sb 2 Te 5 .
[0019] In the resistive memory element according to the invention, the heating material, for instance, is selected from the group including TiO x N y , TiSi x N y , TiAl x N y , TaAl x N y , TaSi x N y , TaO x N y and C (graphitic or DLC). The exact material properties can be tuned by adjusting the material composition properly selecting x and y. Particularly, in selecting stoichiometry of such heating materials, the specific resistivity can be adjusted over a broad range of resistivity values, and, thus specific requirements can be met.
[0020] In the resistive memory element of the invention for use in a resistive memory cell, it is possible to further reduce heating currents with regard to prior art solutions without being limited to a specific technology for fabrication and without adverse effects on crystallization characteristics. Thus, a further reduction in size of the memory element is possible for a memory cell in 5 to 8 F 2 size in convenient silicon CMOS processing, where F is the minimum feature size of the technology used.
[0021] Other and further features of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate present embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention.
[0023] FIG. 1 is a schematic vertical sectional view of an embodiment of a resistive memory element of the present invention; and
[0024] FIG. 2 is a schematic vertical sectional view of another embodiment of a resistive memory element of the present invention.
[0025] Embodiments of the present invention will be described in detail below with reference to the accompanying drawings, where like designations denote like elements.
DETAILED DESCRIPTION
[0026] Referring to FIG. 1 , a resistive memory element includes a resistive memory material and a heating material. Based on a conventional heater electrode geometry, an electrically operated, resistive memory element has a resistive memory material 1 , which in the present embodiment is an alloy having at least one chalcogenid, such as Ge 2 Sb 2 Te 5 . The phase change material 1 is sandwiched between a top electrode 2 and a bottom electrode 3 , i.e., both electrodes adjoin the phase change material in direct electrical contact. Top and bottom electrodes are, for instance, made of TiN or W or the like. In that embodiment, the bottom electrode 3 is formed as heating electrode having a smaller lateral dimension than the top electrode 2 . The bottom electrode 3 is further connected to a plug electrode 4 arranged below of it, for instance, made of W, which is in electric contact with the source-drain-path of a transistor device (not shown in the drawings). Both bottom electrode 3 and plug electrode 4 are surrounded by an isolating material 5 , such as SiO 2 . Within the phase change material 1 , a heating layer 6 for heating the phase change material 1 , for instance, made of TiO x N y , C, TiAl x N y , TiSi x N y , TaSi x N y or the like, is embedded, such that an upper part 1 a and a lower part 1 b of the phase change material 1 is formed. As is illustrated in FIG. 1 , due to the relatively larger thermal diffusivity of the top electrode 2 relative to the bottom electrode 3 , the heating layer 6 is located closer to the top electrode 2 than to the bottom electrode 3 , i.e., the distance between heating layer 6 and top electrode 2 is relatively smaller than the distance between heating layer 6 and bottom electrode 3 .
[0027] In FIG. 1 , in an upward-downward direction referred to as D 1 , the upper part 1 a of the phase change material 1 layer has a thickness of about 10 nm, the lower part 1 b of the phase change material 1 has a thickness of about 20 nm, and the heating layer 6 has a thickness of about 5 nm. Further, the top electrode 2 has a thickness of about 140 nm, the bottom electrode 3 has a thickness of about 100 nm, and the plug electrode 4 has a thickness of about 175 nm. In FIG. 1 , in left-right direction referred to as D 2 , the bottom electrode 3 has a width of about 60 nm, and the plug electrode 4 has a width of about 280 nm.
[0028] Referring to FIG. 2 , another embodiment of the resistive memory element has a resistive memory material and a heating material. Based on a conventional active material-in-via geometry, the electrically operated, resistive memory element has a resistive memory material 1 , which in the present embodiment, as in the embodiment of FIG. 1 , is an alloy containing at least one chalcogenid, such as Ge 2 Sb 2 Te 5 . The phase change material 1 is sandwiched between a top electrode 2 and a plug electrode 4 , i.e., both electrodes adjoin the phase change material in direct electrical contact. The top electrode is, for instance, made of TiN or W or the like, while the plug electrode 4 , for instance, is made of W or the like, and is in electric contact with the source-drain-path of a transistor device (not shown in the drawings). The phase change material 1 is partly filled in a via opening 7 between top electrode 2 and plug electrode 4 . The remaining part of the partly filled via opening 7 is filled with a via opening part 8 of the top electrode 2 . While not shown in FIG. 2 , the via opening 7 can be relatively completely filled with the phase change material 1 . Both via connection 7 and plug electrode 4 are surrounded by an isolating material 5 , such as SiO 2 . Within the phase change material 1 , a heating layer 6 for heating the phase change material 1 , for instance, made of TiO x N y , C, TiAl x N y , TiSi x N y , TaSi x N y , TaAl x N y , TaO x N y or the like, is embedded, such that an upper part 1 a and a lower part 1 b of the phase change material 1 is formed. As is illustrated in FIG. 2 , due to the relatively larger thermal diffusivity of the plug electrode 4 relative to the protruding part 8 of the top electrode 2 , the heating layer 6 is located relatively closer to the plug electrode 4 than to the top electrode 2 , i.e., the distance between heating layer 6 and plug electrode 4 is relatively smaller than the distance between heating layer 6 and protruding part 8 of the top electrode 2 .
[0029] In FIG. 2 , in an upward-downward direction referred to as D 1 , the upper part 1 a of the phase change material 1 layer has a thickness of about 20 nm, the lower part 1 b of the phase change material 1 has a thickness of about 10 nm, and the heating layer 6 has a thickness of about 5 nm. Further, the top electrode 2 (without protruding part 8 ) has a thickness of about 100 nm, the protruding part 8 of the top electrode 2 has a thickness of 100 nm, and the plug electrode 4 has a thickness of about 225 nm. In FIG. 1 , in left-right direction referred to as D 2 , the protruding part 8 of the top electrode 2 , the phase change material 1 and the heating layer 6 each have a width of about 60 nm, and the plug electrode 4 has a width of about 260 nm.
[0030] Numeric simulations using the heater geometry as shown in FIG. 1 and the active material-in-via geometry as shown in FIG. 2 brought the following results:
[0031] In both the above cases, a thermal conductivity of 10 W/m·K, density of 5240 kg/m 3 , specific thermal capacity of 784 J/kg·K and specific resistivity of 5·10 3 Ohm·m for the heating layer made of TiO x N y have been assumed.
[0032] Heater geometry: I reset (current for erasing the memory cell) for 30 nm thickness Ge 2 Sb 2 Te 5 reference without heating layer amounts to about 1200 μA, and with heating layer is reduced to about 882 μA.
[0033] Active material-in-via geometry: I reset (current for erasing the memory cell) for 30 nm thickness Ge 2 Sb 2 Te 5 reference without heating layer amounts to about 665 μA, and with heating layer is reduced to about 175 μA.
[0034] In the resistive memory of the invention using the heating material, the total electric resistivity can be enhanced without having adverse effects on specific characteristics of the resistive memory material.
[0035] While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Accordingly, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
REFERENCE LIST
[0000]
1 Phase change material
1 a Upper part
1 b Lower part
2 Top electrode
3 Bottom electrode
4 Plug electrode
5 Isolating material
6 Heating material
7 Via opening
8 Via part of top electrode | An electrically operated, resistive memory element includes a volume of resistive memory material, adapted to be switched between different detectable resistive states in response to selected enery pulses; means for delivering electrical signals to at least a portion of the volume of resistive memory material; and a volume of heating material for Ohmic heating of the resistive memory material in response to the electrical signals. The volume of heating material is embedded in the volume of resistive memory material. | 6 |
FIELD OF THE INVENTION
The present invention relates to an improved structure of a water bottle-straw assembly and particularly to a water bottle-straw assembly that employs a simple structure and has the advantages of preventing air from being sucked in subsequent suctions, providing better sealing free from water leakage, completely sucking up water in the bottle, and being applicable to water bottles with various capacity depths.
BACKGROUND OF THE INVENTION
In a commercially available water bottle, there is generally provided with a straw assembly for convenience. For example, please refer to FIGS. 1 and 2, which are two side sectional views of a conventional water bottle-straw assembly, illustrating the cap of a lift-lower type used in the assembly is in an open and a closed states, respectively. The straw assembly essentially consists of a cap base 10 and a straw 20 . The cap base 10 can be screwed to the open end of a water bottle 30 , and a circular groove 11 is provided at the center of the cap base 10 . A through hole 12 is fonned on the bottom of the circular groove 11 . The cap base 10 is also provided with a cap 13 of a lift-lower type. The straw 20 goes through the through hole 12 of the circular groove 11 and is capped with a sucker 21 . A spring 22 is disposed between the sucker 21 and the bottom of the circular groove 11 in such a way that the sucker 21 can be pushed up above the cap base 10 by the spring 22 when the cap 13 is in an open state as shown in FIG. 1, and that the sucker 21 can be pushed down into the circular groove 11 when the cap 13 is in a closed state as shown in FIG. 2 . In addition, the lower end of the straw 20 generally approaches the inner bottom of the water bottle 30 .
Although such a water bottle-straw assembly can provide convenience in water drinking, there are several drawbacks as described below.
Because the upper end of the straw 20 simply leads to the lower end thereof, the water sucked up in the straw 20 will flow back to the bottle 30 when a user's mouth no longer contains the sucker 21 , resulting in that the air will immediately fill in the space above the water level in the straw 20 . Consequently, when the user sucks again, he must completely suck the air in the straw 20 before the water in the bottle 30 comes up into his mouth through the straw 20 . By the way, the lower the water level is, the more air is sucked. Users usually suck so much air into their stomachs that they may feel sick during or after drinking. When the cap 13 is in a closed state as shown in FIG. 2, it presses against the upper end of the sucker 21 . However, since there is a gap between the sucker 21 and the circular groove 11 , the water in the bottle 30 can leak out from the circular groove 1 1 through the through hole 12 .
During sucking, users, especially children and babies, may be hurt at their teeth because the sucker 21 is usually made of hard plastics.
Furthermore, the straw 20 will move up and down as the sucker 21 moves up and down due to the opening and closing of the cap 13 . Accordingly, it is usually a principle that the straw 20 is not so long and does not touch the inner bottom of the water bottle 30 when the cap 13 is in aclosed state, as shown in FIG. 2 . Obviously, such a length of the staw 20 always makes a distance between the lower end of the straw 20 and the inner bottom of the water bottle 30 when the cap 13 is in an open state, as shown in FIG. 1 . Therefore, users cannot completely suck the water out of the bottle 30 , and there is always some water left in the bottle 30 after use.
Thus, there is a need to improve conventional water bottles for better sucking.
SUMMARY OF THE INVENTION
The objective of the present invention is to provide an improved structure of a water bottle-straw assembly, which employs a simple structure and has the advantages of preventing air from being sucked in subsequent suctions, providing better sealing free from water leakage, completely sucking up water in the bottle, and being applicable to water bottles with various capacity depths.
In accordance with the present invention, the improved structure of such a water bottle-straw assembly, comprises:
a cap base screwed to the open end of the water bottle body, wherein a through hole and an air inlet are formed on said cap base, a rabbet groove is provided around said through hole beneath said cap base, and said cap base is also provided with a cap of a lift-lower type at its edge;
a suction base made of silicone and being made integral, wherein a flange is formed around said suction base, a suction end is protruded on said suction base, another flange is formed around the low part of said suction end, a valve is provided at the top of said suction end, an air-guiding groove is formed either on said flange or on the corresponding position beneath said cap base, an air inlet valve is provided in said air-guiding groove;
a straw, the tipper end of which is connected into said suction end of said suction base and the lower end of which touches the inner bottom of the water bottle body;
wherein said suction end goes through said through hole of said cap base in such a way that said two flanges of said suction base are rabbetted with said rabbet groove and the edge of said through hole, respectively, and that said suction end is protruded above said cap base; and
wherein said air-guiding groove on said flange corresponds to and is thus air-connected to said air inlet on said cap base.
Moreover, a flexible tube can be telescopically connected to said lower end of said straw, thereby the total length of said straw being adjustable to make said tube touch the inner bottom of the water bottle body by means of telescoping, in order for use in water bottles with various capacity depths.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objectives, features and advantages of the invention will become apparent from the following detailed descnption of preferred embodiment in connection with the accompanying drawings in which:
FIG. 1 is a side sectional view of a conventional water bottle-straw assembly, illustrating the cap of a lift-lower type used in the assembly in an open state.
FIG. 2 is a side sectional view of the assembly shown in FIG. 1, illustrating the cap of a lift-lower type used in the assembly in a closed state.
FIG. 3 is a side sectional view of the water bottle-straw assembly in accordance with the embodiment of the present invention.
FIG. 3A is a partial, enlarged view of area A in FIG. 3 .
FIG. 4 is an exploded view of the assembly shown in FIG. 3, wherein the cap of a lift-lower type used in the assembly is in an open state.
FIG. 5 is a side sectional view of the assembly shown in FIG. 3, wherein the cap of a lift-lower type used in the assembly is in a closed state.
FIG. 6 is a side sectional view of the assembly in accordance with the embodiment of the present invention applied to another water bottle that has a different size from the water bottle shown in FIG. 3 .
It is noted that the drawings of the invention are not to scale. The drawings are merely schematic representations, not intended to portray specific parameters of the invention, rather to illustrate the principles of the invention. The drawings are intended to depict only a typical embodiment of the invention and therefore should not be considered as limiting the scope of the invention.
Reference Numerals of the Elements in the Drawings
10
cap base
44
cap of a lift-lower type
11
circular groove
50
suction base
12
through hole
51
flange
13
cap of a lift-lower type
52
suction end
20
straw
53
flange
21
sucker
54
valve
22
spring
55
air-guiding groove
30
water bottle
56
air inlet valve
40
cap base
60
straw
41
through hole
61
tube
42
air inlet
70
water bottle body
43
rabbet groove
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A water bottle-straw assembly will be described below as a preferred embodiment of the present invention. It should be understood, however, that the present disclosure is to be considered as an exemplification of the principles of this invention and is not intended to limit the invention to the illustrated embodiment
FIG. 3 is an exploded view of the water bottle-straw assembly in accordance with the embodiment of the present invention. FIGS. 4 and 5 are two side sectional views of the assembly shown in FIG. 3 . The assembly comprises a cap base 40 , a suction base 50 , and a straw 60 .
The cap base 40 can be screwed to the open end of a water bottle body 70 . A through hole 41 and an air inlet 42 are formed on the cap base 40 . A rabbet groove 43 is provided around the through hole 41 beneath the cap base 40 . The cap base 40 is also provided with a cap 44 of a lift-lower type at its edge.
The suction base 50 is made of silicone, for example, and is made integral. A flange 51 is formed around the suction base 50 , and a suction end 52 is protruded thereon. Another flange 53 is formed around the low part of the suction end 52 , and a valve 54 , for example of a cross-type, is provided at the top of the suction end 52 . An air-guiding groove 55 is formed either on the flange 51 or on the corresponding position beneath the cap base 40 . An air inlet valve 56 , for example of a cross-type, is provided in the air-guiding groove 55 . The suction end 52 goes through the through hole 41 of the cap base 40 in such a way that the flanges 51 and 53 are rabbetted with the rabbet groove 43 and the edge of the through hole 41 , respectively, and that the suction end 52 is protruded above the cap base 40 . The air-guiding groove 55 on the flange 51 corresponds to and is thus air-connected to the air inlet 42 on the cap base 40 .
The upper end of the straw 60 is connected into the suction end 52 of the suction base 50 . In order for use in water bottles with various capacity depths, a flexible tube 61 is telescopically connected to the lower end of the straw 60 . Accordingly, the total length of the straw 60 can be easily adjusted to make the tube 61 touch the inner bottom of the water bottle body 70 by means of telescoping.
In accordance with the embodiment of the present invention, the flanges 51 and 53 of the suction base 50 are rabbetted with the rabbet groove 43 of the cap base 40 and the edge of the through hole 41 of the cap base 40 , respectively. The suction end 52 is protruded on the suction base 50 . Moreover, the air-guiding groove 55 on the flange 51 corresponds to and is thus air-connected to the air inlet 42 on the cap base 40 so that the air can fluently enter the water bottle body 70 during suction. Hence, users can suck the water fluently.
It is noted that, due to the provision of the valve 54 at the top of the suction end 52 , the air can flow only into the water bottle body 70 through the valve 54 . Thus, when users stop sucking, it is possible to prevent the water sucked up in the straw 60 from flowing back to the water bottle body 70 because the valve 54 automatically close the air path at that time. Consequently, air will not be sucked into an user's mouths in their subsequent suctions. It is also noted that the valve 54 at the top of the suction end 52 and the air inlet valve 56 in the air-guiding groove 55 automatically close the air path while an user does not suck. Therefore, the water bottle body 70 is substantially sealed at that time due to the provision of the valve 54 and the air inlet valve 56 . The water in the bottle is free from leakage even if the bottle is tilt or down.
Furthermore, due to the flexible tube 61 telescopically connected to the lower end of the straw 60 , the total length of the straw 60 can be easily adjusted to make the tube 61 touch the inner bottom of the water bottle body 70 by means of telescoping. Thus, no matter how deep the water bottle is, it is certain that users can completely suck the water out of the bottle without difficulty. No matter the cap 44 is in an open or close state, the straw 60 will not move up and down.
Because the suction base 50 is made of silicone that is relatively softer than plastics, it is safe, especially for children and babies, to use such a suction base.
While the invention has been described with specific reference to the embodiment, someone skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the invention. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A water bottle-straw assembly comprising a screw-threaded cap base including a lift-lower cap attached at one side thereof and a through hole in which a suction base is inserted. The suction base has a protruding suction end having a valve and a flange providing an air guiding groove. A straw is inserted into the suction base and a flexible tube is telescopically connected to the lower end of the straw to allow use with containers of varying sizes. | 1 |
FIELD OF THE INVENTION
This invention relates to binders resistant to fouling and organisms present in an aqueous medium as well as to a process for their preparation.
BACKGROUND OF THE INVENTION
In this description, these binders will be more especially described in their applications to paints or coatings resistant to marine fouling, without this constituting a limitation in any way, since they will also find many advantageous applications if they are applied alone.
The marine organisms which accumulate on marine underwater surfaces cause an increase of weight and roughness, which constitutes a major problem of ship maintenance both for large-tonnage ships and for fishing and pleasure boats. This phenomenon is more generally known under the name of "fouling."
The fight against marine fouling is now carried out by incorporation of biocidal agents (generally tin salts) in protective paints. The biocidal agents are slowly salted out in the marine medium, so they have a limited effectiveness in time and pollution problems.
EP-A-0 156 632 describes a copolymer comprising acrylic or methacrylic esters which can optionally contain quaternary ammonium functions, but the latter, according to the authors, are not bioactive groups responsible for antifouling activity. Introduction of a hydrolyzable ester is claimed to facilitate erosion of the copolymer. Moreover, the copolymer contains organotin compounds introduced by copolymerization (tributyltin methacrylate, TBTM) which are responsible for the antifouling activity.
FR-A-2 510 121 describes a chemical modification of chlorinated natural rubber intended to make it compatible with polyamides which are claimed to be used for their antifouling activity. Chlorinated natural rubbers are now used in anticorrosion primers, but they do not relate to antifouling finishing coats. Generally, chlorinated polymers are often used in binders for marine paints because of their mechanical behavior and their good resistance to water, but they do not intervene in antifouling properties.
The partial prohibition against using antifouling paints containing tin salts, which are toxic elements for marine organisms of plant or animal origin, has been one of the factors inciting inventors to develop replacement paints not exhibiting these defects.
SUMMARY OF THE INVENTION
Thus, the object of the invention is to propose novel binders for coatings resistant to fouling and organisms present in an aqueous medium whose originality consists in the fact that they consist essentially of the association of quaternary ammonium salts and chlorinated vinyl resins.
In a first embodiment, quaternary ammonium salts are incorporated into a coating composition by mixing with chlorinated vinyl resins at a rate of 10 to 20% by weight.
Advantageously, and according to another embodiment of the invention, the quaternary ammonium salts are grafted by a nonhydrolyzable covalent bond onto a chlorinated vinyl resin.
In this second case, the biocidal group acts by contact and, because it is not salted out, it does not exhibit the risk of pollution, particularly for the surrounding medium.
The chlorinated vinyl resin according to the invention is selected from the group consisting of polyvinyl chloride, postchlorinated polyvinyl chloride, polyvinylidene chloride, as well as copolymers of vinyl chloride or from chlorinated rubbers.
Grafting of quaternary ammonium salts on a chlorinated vinyl resin was performed in two steps:
The first step consists in substituting chlorides of the polymer with a molecule comprising a primary or secondary function and a tertiary amine function: ##STR1##
The second step is the quaternization of the tertiary amine function by an alkyl halide: ##STR2##
During the first step of the synthesis, the substitution reaction is in competition with a reaction of elimination of HCl (dehydrochlorination).
Therefore, it was necessary to find a compromise in the experimental conditions so that the substitution/elimination ratio would be most favorable.
It was determined that the percentage of elimination could be reduced to the benefit of the substitution reaction by buffering the medium to lower the pH by about one unit, for example, by adding solid carbon dioxide or para-toluenesulfonic acid.
In the case where R 1 is an aromatic group, very high substitution rates (greater than 50%) could be observed practically without any elimination.
Further, to minimize the risks of oxidation and degradation of the products, a perfectly anhydrous amine must be used and, if possible, handled under inert atmosphere.
The first step can be performed in solution in dimethyl sulfoxide (DMSO), in tetrahydrofuran (THF), xylene or in bulk, the resins being soluble in most of the amines used. In this case, the amine acts both as a solvent and reagent in great excess. The concentration of the resin in the amine can reach several moles per liter. The length of the reaction is obviously linked to the temperature.
Preferably, the operation is at about thirty degrees below the boiling temperature of the amine (temperature at which the proportion of the substitution relative to the elimination is better).
The length of the reaction goes from several days in solution to several hours in bulk.
At the end of the reaction, it can be advantageous to concentrate the medium by distillation under vacuum of the excess amine to facilitate precipitation. The latter is performed depending on the resin considered and the rate of substitution attained either in an excess of methanol or in a great excess of water or better of salt water with vigorous stirring.
By addition of a solvent such as acetone, dichloromethane, chloroform, etc., the medium can be diluted then the mixture poured into water. The polymer remains on the surface of the aqueous phase and it is easy then to rinse it with water several times, by decanting, until a neutral pH is attained (all amine which has not reacted and which gives this basic pH must be eliminated). The polymer is then filtered and dried under vacuum.
Before precipitation, it is thus possible to recover more than 80% by volume of amine that has not reacted (and therefore to concentrate the reaction mixture more). The medium then becomes very viscous. By addition of a solvent (one volume of reaction medium concentrated to 80% per two volumes, for example, of acetone), this medium can be diluted then this solution can be poured into water; the polymer is then in the form of more or less fine powder or fiber, depending on the amount of water, the rate of stirring, the temperature, etc.
At times it is necessary to cool the concentrated reaction medium when acetone is added to it. This acetone can react on the residual amine and give rise to an exothermic reaction. It is also possible to replace acetone with dichloromethane, chloroform or any other solvent of the polymer.
To isolate the polymer after the first step, it is also possible to proceed as follows: the reaction medium, after concentration of 50% by volume by distillation of the excess amine, is poured into the water with stirring. The poorly defined precipitate (coarse grains, sticky product) and swollen with water (very considerable water retention) is then taken up with xylene. By extraction and decanting, this xylene phase is rinsed with salt water to a neutral pH. This organic phase is then dried over a mineral drying agent. The polymer, in solution in xylene, can then be treated directly in a second step (as will be described in example 5). (Optionally the medium can be concentrated by removing the excess xylene by distillation.) Instead of drying the xylene phase, it is also possible to proceed to an azeotropic distillation which will eliminate the water.
The recovered polymer quantitatively is generally entirely soluble in solvents such as xylene, dichloromethane, chloroform, acetone, THF. It can also be purified by successive precipitation and dissolution.
During the second step of this synthesis, an alkyl halide reacts on the tertiary amine function coming from the first step to lead to a quaternary ammonium salt grafted on the resin.
This alkyl halide can be octyl, lauryl, benzyl bromide, etc., including a long linear or aromatic carbon chain.
This reaction can be performed in solution in the xylene, methyl isobutyl ketone, or methanol conventionally used by paint manufacturers or performed in bulk in case the polymer obtained is soluble in the alkyl halide. The concentration of polymer in the medium can amount to several moles per liter.
The reaction temperature can reach 100° C., but it is preferable to be at a temperature on the order of 60°-80° C. to avoid degradation of the product.
The length of the reaction can go up to several hours if a considerable conversion rate is desired.
Several times the formation of an insoluble gelled fraction is observed, which is greater the higher the temperature and the longer the reaction time.
The reaction medium is then poured into an excess of aliphatic hydrocarbon (C 5 -C 7 ). The polymer is isolated by filtering, then dried. The polymer can be purified by redissolution in chloroform, for example, then by reprecipitation in a great excess of heptane. It is advisable to work under inert gas to avoid any risk of alteration of the product.
When this second step is performed in xylene solution, it is not necessary to precipitate the polymer; the latter can be used directly for the formulation of paint (marine paints generally contain xylene, methyl isobutyl ketone and methanol).
Only a concentration of the medium may be necessary before delivery of the binder to the paint manufacturers, by distilling off the excess xylene.
Within the framework of their studies and to determine the properties of antifouling paints according to the invention, a simple test has been developed, making it possible to measure the rate at which a material submerged in seawater is covered with bacteria (the latter constitute a first deposit on which multicellular organisms are then fixed). A count of bacteria, taken from samples of several cm 2 and cultured, makes it possible to obtain the number of bacteria deposited per cm 2 as a function of time.
DETAILED DESCRIPTION OF THE INVENTION
This invention will now be better understood and its advantages will be better understood from the following examples which illustrate it without limiting it in any way.
EXAMPLE 1
To a solution of 1 g of commercial PVC (purified by successive dissolution and precipitation) in 10 ml of THF is added 0.1 g of octyl trimethyl ammonium chloride (3% by moles relative to the PVC).
Small plates of several cm 2 are dipped in this mixture. By evaporation of the solvent, films are obtained which cease to be sticky after forty eight hours. These small plates are immersed in a pan of natural seawater. The number of bacteria deposited at the end of seven days is twenty six times less than that of a reference sample (untreated PVC film).
Under the same conditions, a commercial paint with a base of tin salts exhibits a reduction of the number of bacteria by a factor of 80.
EXAMPLE 2
There is dissolved 3 g of commercial PVC purified by successive dissolution and precipitation (0.048 mole) in 150 ml of DMSO. he dissolution can be accelerated by heating to 50° C. 30.2 ml of 3-dimethylaminopropylamine (0.24 mole) is added at once. The mixture is stirred for six days at ambient temperature.
The yellow polymer, recovered by precipitation in an excess of methanol, is soluble in chloroform and THF.
According to its NMR 1 H spectrum, it comprises 12.5% of grafted 3-dimethylaminopropylamine group. The rate of dehydrochlorination is 15%.
One gram of this amine polymer is dissolved in 100 ml of THF, and 5.44 ml of octyl chloride (0.032 mole) is added. The solution is brought to 60° C. over a period of twenty four hours with stirring. Under these conditions, the partial formation of a gel is observed during the reaction. The soluble fraction (about 70% by weight) is precipitated in a large excess of n-heptane. The polymer, soluble in chloroform and in aromatic solvents, according to its NMR 1 H spectrum, exhibits a rate of quaternary ammonium of molar 7.5% (or a yield of 60% relative to the tertiary amine functions present). The rate of dehydrochlorination is unchanged.
Small plates of some cm 2 are covered with a film of this resin, deposited by coating with chloroform solution. The varnish obtained, which is flexible and bright, is no longer sticky after several hours. The plates are immersed in a basin of natural seawater. The number of bacteria deposited after twenty eight days is eighteen times less than that of a reference sample (untreated PVC film).
Under the same conditions, a commercial marine paint with a base of tin salts causes a reduction of the number of bacteria by a factor of 44.
EXAMPLE 3
In this example, fixing of the dimethylaminopropyl groups is performed as follows: 0.75 g of PVC is dissolved in 30 ml of dimethylaminopropylamine. The mixture is brought to 100° C. over a period of four hours with stirring. At the end of the reaction, about two thirds of the excess amine is eliminated by distillation under vacuum. The concentrated solution is then poured into an excess of salt water. The yellow orange polymer obtained is soluble in chloroform and THF. According to its NMR 1 H spectrum, it comprises 27% of fixed dimethylaminopropylamine groups and the rate of dehydrochlorination is 31%.
The quaternization step is then performed under the conditions described in example 2.
Application of a film of the resin thus obtained to small plates of some cm 2 gives results comparable to those described in example 2.
EXAMPLE 4
1.5 g of a copolymer with a base of vinyl chloride and vinyl isobutyl ether (resin LAROFLEX MP 35 of BASF) is dissolved in 60 ml of dimethylaminopropylamine.
The mixture is brought to 100° C. over a period of four hours with stirring.
Recovery of the polymer is performed under the conditions described in example 3.
The yellow polymer is soluble in chloroform, methylene chloride, THF and acetone. According to its NMR 1 H spectrums, it comprises 11% of dimethylaminopropylamine groups, the rate of dehydrochlorination being 12.5%.
1.2 g of this polymer is dissolved in 30 ml of octyl chloride. After four hours of reaction at 80° C., the solution is concentrated by distillation under vacuum of two thirds of the excess octyl chloride.
The polymer is then precipitated in a great excess of heptane. Its NMR 1 H spectrum indicates the presence of molar 5.5% of fixed quaternary ammonium groups.
The product obtained, tested under the conditions described in example 2, gives comparable results.
EXAMPLE 5
56 g of LAROFLEX MP 35 of BASF is dissolved in 320 ml of dimethylaminopropylamine. In two hours the mixture is brought to 100° C. with stirring. Up to 80% by volume of the unreacted amine is recovered by distillation under vacuum.
120 ml of acetone is slowly added with stirring and cooling in ice water and the solution is slowly poured into 500 ml of water with stirring.
The yellow polymer, having a fibrous appearance, floats on the surface and it is rinsed with water, by decanting, to a neutral pH. It is filtered and dried under vacuum.
40 g of this polymer is added, with vigorous stirring, to a solution of 30 g of xylene, 20 g of methyl isobutyl ketone and 10 g of methanol.
Then 18.5 g of octyl bromide is added and heated to 60° C. for eight hours. The binder thus prepared is added to other standard ingredients of a paint such as fillers, plasticizers, pigments, and the like.
The plates, covered with this paint and submerged for several months in the sea, exhibit an appearance remarkably free of marine fouling in comparison with plates covered with antifouling paints having a base of tin salts.
The binders obtained for embodying the process described above make it possible to obtain, once the standard ingredients of paints and especially solvents, pigments, etc. are added, antifouling paints whose biocidal effectiveness, comparable with that of standard paints with a base of tin salts, does not exhibit the drawbacks usually encountered with the latter, particularly with regard to pollution, which constitutes a very important advance in the field of marine paints, and more generally, for all coatings intended to be in contact with an aqueous medium containing living organisms such as bacteria, fungi, yeasts, algae, shellfish, and the like.
These binders therefore also find advantageous applications in the field of bacterial anticorrosion coatings, as well as in the field of coatings with fungicidal properties.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and therefore such adaptations and modifications are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. | Binders comprising the association of chlorinated vinyl resins and quaternary ammonium salts are resistant to corrosion, fouling, and organisms in an aqueous medium.
The binders are obtained by substituting the chlorines of the polymer with a molecule having a primary or secondary amine function and a tertiary amine function, and then quaternizing the tertiary amine function by an alkyl halide.
The binders thus obtained are useful in the production of coatings resistant to fouling and organisms present in an aqueous medium, of bacterial anticorrosion coatings and coatings with fungicidal properties. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. provisional patent application No. 61/367,483 filed Jul. 26, 2010, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention relates generally to high voltage power supplies, and more particularly, to a dual transformer and ladder rectifier power supply for powering a magnetron in ultraviolet radiation (UV) curing lamp assemblies.
BACKGROUND OF THE INVENTION
Radiant energy is used in a variety of manufacturing processes to treat surfaces, films, and coatings applied to a wide range of materials. Specific processes include, but are not limited to, curing (i.e., fixing, polymerization), oxidation, purification, and disinfection. Processes using radiant energy to polymerize or effect a desired chemical change is rapid and often less expensive in comparison to a thermal treatment. The radiation can also be localized to control surface processes and allow preferential curing only where the radiation is applied. Curing can also be localized within the coating or thin film to interfacial regions or in the bulk of the coating or thin film. Control of the curing process is achieved through selection of the radiation source type, physical properties (for example, spectral characteristics), spatial and temporal variation of the radiation, and curing chemistry (for example, coating composition).
A variety of radiation sources are used for curing, fixing, polymerization, oxidation, purification, or disinfections due to a variety of applications. Examples of such sources include, but are not limited to, photon, electron, or ion beam sources. Typical photon sources include, but are not limited to, arc lamps, incandescent lamps, electrodeless lamps and a variety of electronic (i.e., lasers) and solid-state sources.
An apparatus for irradiating a surface with ultraviolet light includes a lamp (e.g., a modular lamp, such as a microwave-powered lamp having a microwave-powered bulb (e.g., tubular bulb) with no electrodes or glass-to-metal seals), the lamp having reflectors to direct light (photons) on to the surface. The source of microwave power is conventionally a magnetron, the same source of microwaves typically found in microwave ovens. The microwave-powered bulb typically receives microwaves generated by the magnetron through an intervening waveguide.
Conventional power supplies for magnetrons include a variety of designs. A typical design used for powering microwave ovens includes a one step-up resonant laminated transformer, a high voltage diode, and a high voltage capacitor. The transformer/capacitor combination takes a 50 Hz/60 Hz line voltage and outputs a 50/60 Hz half wave pulsed DC voltage or a 100% ripple DC voltage. It has the advantage of low cost, but includes the disadvantages of being large and heavy with a single level of output power.
A second design employs a silicon-controlled rectifier (SCR) to control an amount of phase of an input power sine waveform that may be applied to a laminated transformer. The output windings of the laminated transformer steps up the input voltage which is applied to a full diode bridge. The output is a 50 HZ/60 Hz full wave rectified pulsed DC voltage or 100% ripple DC voltage.
A third possible design is a switching mode power supply which provides a high power DC voltage with low ripple. Conventional high voltage, switching mode power supplies suffer from a number of problems. Because of a high working frequency (>20 KHz), a high frequency, high power single output winding ferrit transformer is needed, along with a small number of high voltage, fast recovery diodes arranged in a diode bridge. The small number of high power, high frequency diodes dissipate a large amount of power. As a result, it is necessary to employ a ferrit transformer with multiple secondary windings coupled to a large number of diode bridges, each comprising 2 or 4 lower voltage diodes as shown in FIG. 1 .
Referring now to FIG. 1 , a portion of a high voltage switching mode DC power supply 10 includes an AC pulsed input source 12 feeding a primary winding of a multiple output winding laminated transformer 14 . The multiple output windings 16 a - 16 l feed a plurality of full-wave rectified diode bridge circuits 18 a - 18 l (also labeled DB 1 -DB 12 ) requiring a total of 64 diodes. A rippled approximate DC output voltage is smoothed and high frequency components from the switching power supply are removed by a plurality of filter circuits 20 a - 20 l each comprising at least a capacitor and an inductor, labeled C 1 -C 12 (references 22 a - 22 l ) and L 1 -L 12 (references 24 a - 24 l ), respectively.
Since there is typically a long cable between a power supply and a magnetron in a UV curring lamp assembly, the outputs of the secondary windings 16 a - 16 l of the multiple winding transformer 14 include a high level of high frequency components. For the power supply 10 to drive a magnetron with low frequency DC power with a long transmission cable (not shown), it is necessary to employ a large number of inductors 24 a - 24 l and capacitors 22 a - 22 l , as well as 12 RC snubbers (not shown) employed as filters to remove high frequency components. Thus, a large number of diodes, inductors and capacitors need to be employed, which is expensive, consumes a large amount of board space, and reduces reliability.
Accordingly, what would be desirable, but has not yet been provided, is an inexpensive high voltage and power output DC power supply having a low component count.
SUMMARY OF THE INVENTION
The above-described problems are addressed and a technical solution achieved in the art by providing a high voltage, high power output power supply for driving a magnetron in a UV curing lamp assembly. The high voltage, high power output power supply includes two intermediate frequency (200-400 Hz) low voltage sinusoidal power sources that are configured to drive the primary windings of a dual laminated transformer. The low voltage sinusoidal power sources are configured to have different phases. The out-of-phase low voltage sine wave sources are converted to high voltage sine waves on the secondary windings of the dual laminated transformer having the same phase difference relationship. A single rectifier comprising six high voltage diodes, called a ladder rectifier, combines the two out-of-phase sine waves into a single, approximately DC output signal.
The ladder rectifier rectifies the two sine wave AC output sources into one of various modes of DC power, which range from high output voltage to high output current depending on a predetermined phase difference between the two input sine wave sources. The approximate DC output signal exiting the ladder rectifier contains a ripple with intermediate frequencies, which cover the spectrum range of 400 Hz to 6.4 KHz. As a result, no filtering inductors or capacitors are needed following the ladder rectifier, thereby providing a low cost, low component count solution for driving a magnetron in a UV curing lamp assembly. The circuit is operable to supply high voltage, high power over a long cable between the power supply and the magnetron.
By modulating a phase difference between two input sine wave power sources, the approximate DC output signal exiting the ladder rectifier may be alternated between a number of output modes: (1) a low ripple mode having an input power source phase difference of 60° and having an output voltage ripple as low as 13.84%; (2) a high current mode having an input power source phase difference of 0°; (3) a high voltage mode having an input power source phase difference of 180°; or (4) an intermediate mode with a ripple in the range of about 13.84% to about 100%. The mode changes may be implemented dynamically using hardware and/or software.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily understood from the detailed description of an exemplary embodiment presented below considered in conjunction with the attached drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 depicts a portion of a conventional high voltage switching mode power supply for driving a magnetron in UV curing applications;
FIG. 2 shows a high level block diagram of a power supply for driving a magnetron for UV curing applications, according to an embodiment of the present invention;
FIG. 3 shows a detailed circuit schematic of the power supply of FIG. 2 which employs a ladder rectifier circuit, according to an embodiment of the present invention;
FIG. 4 is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 60° (minimum ripple mode);
FIG. 5A is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 30° (330°);
FIG. 5B is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 0° (360°);
FIG. 5C is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 90° (270°);
FIG. 5D is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 120° (240°);
FIG. 5E is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 150° (210°);
FIG. 5F is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit of FIGS. 2 and 3 having a phase difference between V 1 and V 2 of 180°;
FIG. 6A depicts an equivalent circuit for the ladder rectifier of FIG. 3 in a maximum current mode;
FIG. 6B depicts an equivalent circuit for the ladder rectifier of FIG. 3 in a maximum voltage mode;
FIG. 7 is a block diagram of a suitable circuit known in the art for providing each of the 200-400 Hz AC input power sources of FIGS. 2 and 3 from an input 50/60 Hz power line; and
FIG. 8 is a circuit schematic diagram of a suitable circuit for generating the 200-400 Hz AC power sources of FIGS. 2 and 3 from an input 50/60 Hz power line.
It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows a high level block diagram and FIG. 3 shows a detailed circuit schematic of a power supply 30 for driving a magnetron for UV curing applications, according to an embodiment of the present invention. Referring now to FIGS. 2 and 3 , the power supply 30 includes a pair of modulated AC power sources 32 a , 32 b , each having the substantially the same predetermined amplitude and frequency, but having a variable phase relationship. The AC power sources 32 a , 32 b , are electrically connected to a pair of input windings 34 a , 34 b of a dual laminated transformer 36 , or, alternatively, matched transformers 37 a , 37 b (also labeled T 1 and T 2 ), respectively. The dual laminated transformer 36 steps up the voltage of the AC power sources 32 a , 32 b on a pair of output windings 38 a , 38 b . The output windings 38 a , 38 b are electrically connected to a pair of input ports 40 a , 40 b of a ladder rectifier circuit 42 to be described hereinbelow. The ladder rectifier circuit 42 comprises a total of six diodes 44 a - 44 f (also labeled D 1 -D 6 , respectively), configured as shown. The ladder rectifier circuit 42 has a single DC output port 46 .
As a non-limiting example of the operation of the power supply 30 , V DC is defined as the voltage across output port 46 , V is the peak voltage present across either of the pair of output windings 38 a , 38 b , and V 1 and V 2 are the instantaneous voltages across each of the pair of output windings 38 a , 38 b , respectively. At any one moment, V 1 =V sine θ and V 2 =V sine (θ−Φ), where θ is an angle within one period of sinusoidal wave of V 1 and Φ is the phase difference between V 1 and V 2 . When Φ is a predetermined value, current may pass through the ladder rectifier circuit 42 in one of six different paths as follows:
When V 1 >0 and V 2 <0, D 1 , D 4 and D 5 (i.e., 44 a , 44 d , and 44 e , respectively) are forward biased, while the diodes D 2 , D 3 , and D 6 (i.e., 44 b , 44 c , and 44 f , respectively) are reverse biased. As a result, current flows though D 1 , D 4 and D 5 , such that the output voltage is V DC =V 1 +|V 2 |=V sine θ+|V sine (θ−Φ)|=V[sine θ−sine (θ−Φ)].
When V 1 >V 2 >0, D 1 , D 4 and D 6 (i.e., 44 a , 44 d , and 44 f , respectively) are forward biased, while the diodes D 2 , D 3 , and D 5 (i.e., 44 b , 44 c , and 44 e , respectively) are reverse biased. As a result, current flows though D 1 , D 4 and D 6 , such that the output voltage is V DC =V 1 =V sine θ.
When V 2 >V 1 >0, D 1 , D 3 and D 6 (i.e., 44 a , 44 c , and 44 f , respectively) are forward biased, while the diodes D 2 , D 4 , and D 5 (i.e., 44 b , 44 d , and 44 e , respectively) are reverse biased. As a result, current flows though D 1 , D 3 , and D 6 , such that the output voltage is V DC =V 2 =V sine (θ−Φ).
When V 1 <0 and V 2 >0, D 2 , D 3 and D 6 (i.e., 44 b , 44 c , and 44 f , respectively) are forward biased, while the diodes D 1 , D 4 , and D 5 (i.e., 44 a , 44 d , and 44 e , respectively) are reverse biased. As a result, current flows though D 2 , D 3 , and D 6 , such that the output voltage is V DC =|V 1 |+V 2 =|V sine θ|+V sine (θ−Φ)=V[sine (θ−Φ)−sine θ].
When V 1 <V 2 <0, D 2 , D 3 and D 5 (i.e., 44 b , 44 c , and 44 e , respectively) are forward biased, while the diodes D 1 , D 4 , and D 6 (i.e., 44 a , 44 d , and 44 f , respectively) are reverse biased. As a result, current flows though D 2 , D 3 and D 5 , such that the output voltage is V DC =|V 1 |=|V sine θ|=−V sine θ.
When V 2 <V 1 <0, D 2 , D 4 and D 5 (i.e., 44 b , 44 d , and 44 e , respectively) are forward biased, while the diodes D 1 , D 3 , and D 6 (i.e., 44 a , 44 c , and 44 f , respectively) are reverse biased. As a result, current flows though D 2 , D 4 and D 5 , such that the output voltage is V DC =|V 2 |=|V sine (θ−Φ)|=−V sine (θ−Φ).
In different time intervals, the voltage across output port 46 , V DC , may be either V 1 or V 2 from one transformer (whichever amplitude is larger than that of the other) or the voltage summation |V 1 |+|V 2 | from two transformers together when V 1 and V 2 are inverted. The instantaneous phase difference between the sinusoidal waveforms of the voltages V 1 and V 2 across the pair of the output windings 38 a , 38 b , is the factor that determines the DC output mode of the ladder rectifier circuit 42 . When the phase difference is fixed, the output mode (i.e., the RMS voltage and ripple voltage) is fixed.
FIG. 4 is a graph of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit 42 , respectively. The waveform 50 is the voltage at the output winding 38 a of the dual laminated transformer 36 (also labeled HV AC output I); the waveform 52 is the voltage at the output winding 38 b of the dual laminated transformer 36 (also labeled HV AC output II); and the waveform 54 is a portion of the composite voltage at the a DC output port 46 of the ladder rectifier circuit 42 , V DC (also labeled HV DC output). The waveform 54 exhibits a distinct ripple. When the phase difference between waveforms 50 and 52 is about Φ=60°, one period of the output waveform 54 may be divided into six time sections, S 1 , S 2 , S 3 , S 4 , S 5 and S 6 , each section covering 60 degrees of phase and described as follows:
In time section S 1 , 0<θ<60°, V 1 >0 and V 2 <0, and output current passes through D 1 , D 4 and D 5 . Both of the output windings 38 a , 38 b provide power to the load and V DC =V [sine θ−sine (θ−60°)].
In time section S 2 , 60°<θ<120°, V 1 >V 2 >0, and output current passes through D 1 , D 4 and D 6 . Only the output windings 38 a provides power to the load and V DC =V 1 =V sine θ.
In time section S 3 , 120°<θ<180°, V 2 >V 1 >0, the output current passes through D 1 , D 3 and D 6 . Only the output windings 38 b provides power to the load. V DC =V 2 =V sine (θ−60°).
In time section S 4 , 180°<θ<240°, V 1 <0 and V 2 >0, the output current passes through D 2 , D 3 and D 6 . Both of the output windings 38 a , 38 b provide power to the load and V DC =V [sine (θ−60°)−sine θ].
In time section S 5 , 240°<θ<300°, V 1 <V 2 <0, the output current passes through D 2 , D 3 and D 5 . Only the output windings 38 a provides power to the load. V DC =−V sine θ.
In time section S 6 , 300°<θ<360°, V 2 <V 1 <0, the output current passes through D 2 , D 4 and D 5 . Only the output windings 38 b provides power to the load. V DC =−V sine (θ−60°).
For the waveforms of FIG. 4 , Φ=60°, which corresponds to a minimum ripple mode, where the percentage DC output ripple is about 13.84% in theory. The output ripple is defined as the percentage of peak-to-peak voltage of ripple divided by the RMS voltage value of a corresponding DC output. In the example of minimum ripple, using a unity V value, i.e., V=1, the ripple may be calculated by the formula (1−sine (90°−60°/2))/RMS of V DC =(1−0.866)/0.968=13.84%.
FIGS. 5A-5F are graphs of a set of voltage waveforms at both the inputs and output of the ladder rectifier circuit 42 , respectively, for various phase differences between V 1 and V 2 , according to an embodiment of the present invention, wherein like reference numbers correspond to similar waveforms. In general, given an arbitrary phase difference between V 1 and V 2 , the time sections, S 1 -S 6 are not divided into six equal sections. The width of the time sections S 1 -S 6 depends upon the amplitude relationship between V 1 and V 2 . The only other equal size time sections occur when Φ=0° or 180°.
At a phase difference of Φ=0°, the DC output voltage V DC =|V 1 |=|V 2 |=V| sine θ| as shown in FIG. 5B . When |V 1 |=|V 2 | with zero phase difference, there are only two time sections, S 1 and S 2 of waveform 54 . In time section S 1 , 0<θ<180°, and V 1 =V 2 >0. Output current passes through D 1 , D 3 , D 4 and D 6 , and V DC =V sine θ. In time section S 2 , 180<θ<360°, V 1 =V 2 <0. Output current passes through D 2 , D 3 , D 4 and D 5 , and V DC =−V sine θ. The output current is provided by both T 1 and T 2 , and each transformer transmits half of the current all of the time. Therefore, when Φ=0°, the ladder rectifier circuit 42 is in a maximum current mode, which is equivalent to the circuit depicted in FIG. 6A .
At a phase difference Φ=180°, the DC output voltage is V DC =|V 1 |+|V 2 |=2 V| sine θ| as shown in FIG. 5F . When |V 1 |=|V 2 | with 180° phase difference, there are only two time sections S 1 and S 2 of waveform 54 . In time section S 1 , 0<θ<180°, V 1 >0 and V 2 <0, V DC =V 1 −V 2 =V[sine θ−sine (θ−180°)]=2 V sine θ. In time section S 2 , 180<θ<360°, V 1 <0 and V 2 >0, V DC =−V 1 +V 2 =V[sine (θ−180°)−V sine θ]=−2 V sine θ. The output power is provided by both T 1 and T 2 transmit equal current and double the voltage of either V 1 or V 2 . Therefore, when Φ=180°, the ladder rectifier circuit 42 is in a maximum voltage mode, which is equivalent to the circuit depicted in FIG. 6B .
In summary, embodiments of the present invention may be developed as a power supply with multiple output features. Changing the phase difference between the modulated power sources AC 1 and AC 2 , may represent the following modes:
Φ=60° phase difference providing a low ripple mode with 13.84% ripple. Φ=0° phase difference providing a high current mode with 100% ripple. Φ=180° phase difference providing a high voltage mode with 100% ripple.
Other phase differences provide various modes ranging between high current mode and high voltage mode with ripple ranging between about 13.84% and about 100%.
For high power applications, a block diagram of a suitable circuit 60 known in the art for providing each of the 200-400 Hz AC power sources 32 a , 32 b of FIGS. 2 and 3 from an input 50/60 Hz power line is depicted in FIG. 7 . The input 50/60 Hz power line voltage 62 is passed through a rectifier and filter circuit 64 , which converts the input power line voltage to an approximate DC power 66 . The approximate DC power 66 is chopped into a PWM (Pulse Width Modulation) sine wave 70 , which is a series of pulses resulting in a sine-like flux density waveform using a full bridge IGBT (Insulated Gate Bipolar Transistor) switch 68 . The chopping frequency of the full bridge IGBT switches is at least 100 times that of the PWM sine wave 70 frequency. For example, if the frequency of PWM sine wave is 300 Hz, the chopping frequency is more than 30 KHz. This PWM sine wave 70 in the form of a smooth sine wave 74 having a frequency in the range of 200 Hz to 400 Hz is produced by a low pass filter 72 . The output signal 74 is fed back to the full bridge switcher circuit 68 by a sine wave modulator circuit 76 .
Alternatively, a suitable circuit for generating both of the 200-400 Hz AC power sources 32 a , 32 b of FIGS. 2 and 3 from an input 50/60 Hz power line is depicted in FIG. 8 .
It is to be understood that the exemplary embodiments are merely illustrative of the invention and that many variations of the above-described embodiments may be devised by one skilled in the art without departing from the scope of the invention. | A power supply for use in a UV curing lamp assembly is disclosed. The power supply is powered by two intermediate frequency (200-400 Hz) low voltage sinusoidal power sources that drive the primary windings of a dual laminated transformer. The low voltage sinusoidal power sources are configured to have different phases. The out-of-phase low voltage sine wave sources are converted to high voltage sine waves on the secondary windings of the dual laminated transformer having the same phase difference relationship. A single rectifier comprising six high voltage diodes, called a ladder rectifier, combine the two out-of-phase sine waves into a single, approximately DC output power source. By modulating a phase difference between two input sine wave power sources, the approximate DC output voltage exiting the ladder rectifier may be alternated between a low ripple mode of about a 13.84% ripple, a high current mode, a high voltage mode, and an intermediate mode with a ripple in the range of about 13.84% to about 100%. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
FIELD OF THE INVENTION
The invention relates to systems and methods for remotely displaying graphical data, and more particularly to techniques for network transmission and execution of three-dimensional graphical data through a distributed application.
BACKGROUND OF THE INVENTION
As business moves toward distributed working environments, and as transmission of electronic data becomes a valuable business tool, it becomes increasingly important to efficiently transport various types of data through computer networks. Transmission of graphical data may pose unique challenges for a number of reasons, including the relatively large size of various types of graphical data and relatively slow and unreliable network transmission bandwidths. Moreover, the size of the graphical data handled by conventional software applications has increased exponentially, making it impracticable to work with local graphical data from remote locations since there is no economical, efficient, and secure way to remotely access the data.
Graphical data may be stored in a computer as a three dimensional (3-D) graphical model, which is a 3-D representation of a real or computer-generated object. Normally, a particular view of the 3-D graphical model is computed using high-end computer hardware, software, and high-end graphics accelerators before it can be displayed to a user in the form of a two-dimensional (2-D) image. The terms display and image may be used interchangeably when reference is made to a user, client and server. The process of extracting a 2-D image from a 3-D graphical model often includes a technique known as rendering. Rendering is the process of creating views from selected viewing angles and adding 3-D visual cues and qualities, such as lighting, textures, shadows, color and image attributes, stereographic perception, animation, and motion-parallax, to the extracted 3-D graphical model in order to enhance the 2-D image understanding of the model. One technique for rendering graphics is called ray tracing. Another type of rendering is scanline rendering, which renders images one horizontal line at a time instead of object-by-object as in ray tracing.
Various techniques exist for the transmission of, or remote display of, graphical data. These techniques may be implemented on a network of computers. The network of computers may include a server, which is a computer running a particular graphics application and managing various resources, and one or more clients, which are computers that rely on the server to perform one or more operations. Alternatively, the network of computers may include a plurality of nodes. The nodes may be computers that are configured to share information without functioning in a structured client-server relationship.
Various image compression techniques may be used to reduce the bandwidth required for transmitting 3-D models or 2-D images locally or across a network. For example, a 3-D model or 2-D image may be compressed at a server or at a first node and transmitted using hardware image compression and hardware data compression techniques. The compressed data may then be decompressed at a client or at a second node in order to image the original data. Conventional image compression techniques, such as transform coding, vector quantisation, segmentation and approximation, spline approximation, wavelet compression, or fractal coding, often lead to lossy or distorted images. In addition, lossy techniques often lead to image degradation at each compression stage. As a result, lossless image compression techniques, including run-length encoding, Huffman encoding, Lempel/Ziv coding, or area coding, were developed.
These conventional techniques, nevertheless, suffer from inherent disadvantages. For example, both the server or first node and the client or second node must perform a compression or decompression step, which is an inefficient use of computing or computer resources. Furthermore, some conventional techniques may be difficult to implement, particularly across multiple heterogeneous platforms normally found in all computing environments. Moreover, lossless image compression techniques may suffer from compression ratios that are not as high as conventional lossy techniques.
U.S. Pat. No. 6,219,057 describes a collaborative work environment for allowing remote users to manipulate a 3-D model using conventional techniques. In this system, each node or client requires its own local copy of the original 3-D model. A local copy of the original 3-D model is rendered at each node or client. Each user may manipulate its local copy of the original 3-D model using a transformation matrix. The transformation matrix is a set of data that represents a manipulation of the original 3-D model. The transformation matrix is used to communicate the viewing position and orientation of the manipulated 3-D model to other users, who use the information to render a new local copy based on the application of the transformation matrix to the original local copy. The system disclosed in the '057 patent is disadvantaged to the extent that it requires significant system resources at each node in the network. For example, each node requires high-end graphics-specific hardware that is sufficient to render the 3-D model. In addition, the rendering operation may require additional memory, system bus bandwidth, and other resources on each node in the network. This usually affects the performance of other applications running on each node.
Furthermore, the nature of the collaborative environment described by the '057 patent may not be practical when some of the 3-D model information is confidential or cannot reside on the client or node because the 3-D model is comprised of data that exceeds the system capacity of the client or node.
Other conventional systems that are available for displaying 3-D graphical data include OpenGL Performer® and OpenGL Vizserver™—both applications offered by Silicon Graphics, Inc. (SGI®). OpenGL Performer® includes a “Dynamic Video Resolution” feature that reduces the size of the rendered image, and correspondingly, the number of rendered pixels. As a result, the speed (frame rate) at which all processing is completed before updating the display with a new image is enhanced. Afterwards, specialized SGI® video hardware enlarges the images to the original size. This is accomplished by using a technique known as bipolar filtering to enlarge the image. In this way, the image is the correct size, but it contains a reduced number of pixels.
OpenGL Performer® is, nevertheless, disadvantaged to the extent that it requires specialized SGI video hardware on any machine that displays an object image. Furthermore, this system does not enable remote rendering, but is, rather, optimized to achieve high frame rates locally. While it can be used in conjunction with remote-enabling products in order to transmit 3-D graphics information, this requires enlarging the image at each node in the network. Therefore, each node must contain specialized video hardware. OpenGL Vizserver™ is similarly disadvantaged. For example, OpenGL Vizserver™ requires specialized hardware in the form of multiple (five) compression modules that compress/decompress the frames of a rendered 3-D graphics model. These compression modules reside at the client and server thus, reducing performance at each end when performing other necessary tasks and interacting with the 3-D graphics model. OpenGL Vizserver™ may also require additional customized modules which adversely impact the system resources of the client and server. In either application using OpenGL Performer®, OpenGL Vizserver™, or both, the cost of implementing such systems is significant.
Another example of a conventional system for displaying 3-D graphical data includes EarthCube® RemoteViz offered by Landmark Graphics Corporation. Like other conventional remote collaboration systems, EarthCube® RemoteViz requires specialized hardware in the form of image based or video based compression packages that are expensive and restrict the client and server system resources from performing other necessary functions.
As demonstrated by the state of the art, there is a need, among other things, for an efficient system that can remotely display 3-D graphical data through a distributed application, however, does not require specialized hardware or software on every node in the network. There is also a need for a single executable application that may be used in a collaborative way, yet may selectively grant control to remote users and runs on most existing client platforms and operating systems. In short, there is a need for a system that operates on most hardware platforms and enables high remote frame rates, transparent remote collaboration processes, and per-component adaptive resolutions while eliminating the need for any client processes, daemons, hardware image compression, software image compression, stream compression and/or data compression.
SUMMARY OF THE INVENTION
An embodiment of the invention addressing these and other needs in the art includes a method of imaging graphical data on one or more clients. The method includes rendering 3-D graphical information in the form of a 3-D model at a local server and using a local server graphics accelerator, sometimes referred to herein as a graphics card, to reduce the network bandwidth requirements (transmission size) of the graphical information by dynamically processing and applying a scaling factor to the 3-D graphical information. The method further includes transmitting the scaled 3-D graphical information and/or other information from the server's graphics accelerator memory to at least one client's graphics accelerator memory and re-scaling the 3-D graphical information to display a mirror image of the original 3-D graphical information to all available clients.
In one particular embodiment, using the local server graphics accelerator to process and apply a scaling factor to the 3-D graphical data includes retrieving the rendered graphic accelerator memory information from the server and binding the graphical information into texture memory to form a texture map, or directly rendering to a texture. This also includes rendering the graphical information into a memory buffer of the server's graphic accelerator, determining a client's native graphics card-pixel format, and reformatting the pixel format of the 3-D graphical information to match the client's native pixel format.
In another embodiment, the invention includes computer-executable instructions, executable to perform the steps of rendering graphical information in the form of a 3-D model at a local server and exclusively using a local server graphics accelerator to reduce the network bandwidth requirements of the 3-D graphical information by dynamically processing and applying a scaling factor to the 3-D graphical information. The computer-executable instructions are further executable to perform the steps of transmitting the scaled 3-D graphical information and/or other information from the server's graphics accelerator memory to at least one client's graphics accelerator memory and re-scaling the 3-D graphical information to display a mirror image of the original 3-D graphical information to all available clients.
In yet another embodiment, a server system is used for displaying graphical data at a remote client and includes a 3-D application rendering module configured to render graphical information, a 3-D graphics accelerator configured to reduce the bandwidth requirements of the graphical information by dynamically processing and applying a scaling factor to the graphical information, and a framebuffer memory configured to store the scaled 3-D graphical information. This system may also include a windows application program interface (API) configured to transmit window system and graphic protocol to the client to enable the client to open one or more display windows. The system further includes a graphics API configured to transmit a scaled-down image of the 3-D graphical information from the framebuffer memory to the client.
In yet another embodiment, a method for displaying graphical data at a client includes receiving windows protocols from a server, receiving pre-rendered 3-D graphical information from the server, and mapping the 3-D graphical information directly into a graphics accelerator memory. The method also includes executing the window system protocol and displaying the pre-rendered 3-D graphical information.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, in which like elements are referenced with like reference numerals, and in which:
FIG. 1 is a block diagram of a system for remotely displaying graphics in accordance with an embodiment of the invention.
FIG. 2 is a block diagram of a server system in accordance with an embodiment of the invention.
FIG. 3 is a block diagram of a client system in accordance with an embodiment of the invention.
FIG. 4 is a block diagram of a server graphics accelerator in accordance with an embodiment of the invention.
FIG. 5 is a flow chart depicting a method for remotely displaying graphics in accordance with an embodiment of the invention.
FIGS. 6 a–f illustrate enabled networking environments in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 is a block diagram of a system for remotely displaying graphics in accordance with an embodiment of the invention. The system may include a 3-D graphics application server 100 and 3-D graphics client 102 , which are referred to herein as the server 100 and client 102 . In some applications, the server 100 and client 102 may be referred to collectively as nodes. The server 100 may be any computer that is configured to run a distributed application and remotely display graphical data and other information at the client 102 . The server 100 may store a 3-D model to be rendered and imaged to remote clients. The server 100 may also manage resources that are used by one or more of the clients 102 . These resources may include specialized rendered graphical data and other information generated by the distributed application.
The client 102 may be a computer that uses resources provided by the server 100 . The client 102 may be configured to remotely display graphical data. In one embodiment, the client 102 may be configured to remotely display graphical data rendered exclusively by the server 100 and based on a 3-D model stored on the server 100 . In this embodiment, the client 102 may be configured to display the graphical data using a windows API to execute windows and other graphics protocols communicated by the server 100 . This may allow the client 102 to remotely display graphical data without actually running the distributed application, and without running a daemon or other process. In other embodiments, the client 102 may itself function as a server in conjunction with other computers.
The server 100 may be connected to the client 102 via a network 104 . The network 104 may be any logical connection that enables the server 100 and client 102 to exchange information. In one embodiment, the network 104 may comprise a local area network (LAN), a wide area network (WAN), the internet, or another network. The network 104 may also comprise a wired network, a wireless network, or some combination thereof.
The server 100 may include an application rendering window 106 , and 3-D graphics accelerator 110 . The application rendering window 106 contains memory of a projection view image 108 that represents the rendered 3-D model. The projection view image 108 is processed by the 3-D graphics accelerator 110 to produce a scaled down image 112 that is stored in the application rendering window 106 at the same location. The 3-D graphics accelerator 110 may include specialized graphics hardware designed to manipulate graphical data stored in its memory. Depending on the type of memory used by the 3-D graphics accelerator 110 , the application rendering window 106 may be used to display the scaled-down image 112 to a user at the server 100 , or may be made totally invisible to the user. The scaled-down image 112 stored by the application rendering window 106 may be transmitted via the network 104 to a 3-D graphics accelerator 114 for the client 102 . Transmitting the scaled-down image 112 may include simultaneously transmitting additional information, such as windows protocols, user interface (UI) information, or other application information directly from the memory of the 3-D graphics accelerator 110 to the memory of the 3-D graphics accelerator 114 .
The 3-D graphics accelerator 110 normally includes any commercially available high performance graphics accelerator, and the 3-D graphics accelerator 114 may include any OpenGL® compatible games-class graphics accelerator such as the GeForce® and Quadro® graphics cards marketed by NVIDIA®, which are otherwise well known for their local image processing and editing capabilities. The 3-D graphics accelerator 110 and 3-D graphics accelerator 114 include memory and a GPU. In one embodiment, the memory for the 3-D graphics accelerators 110 and 114 may include a framebuffer, textures windows, and other memory objects. Alternatively, these objects may exist as memory independent from the 3-D graphics accelerator.
In reference to FIG. 1 , the application rendering window 106 resides in the memory of the 3-D graphics accelerator 110 at the server 100 . Similarly, the remote application rendering window 118 resides in the memory of the 3-D graphics accelerator 114 at the client 102 . The 3-D graphics accelerator 114 may be configured to substantially reproduce the projection view image 108 in the form of a scaled-up image 116 . The scaled-up image 116 may then be displayed on the remote application rendereing window 118 .
FIG. 2 is a block diagram of the server 100 in accordance with an embodiment of the invention. The server 100 may include an operating system 202 . The operating system 202 may include a graphics API 204 and a windows/graphics protocol 206 . The graphics API 204 may include a set of routines, protocols, and tools for building graphics software applications, such as X11 and Open GL®, which are open source software. The windows/graphics protocol 206 may include a set of routines, protocols, and tools for managing display windows for various applications, such as the open source X-server, or any other windows emulator.
The server 100 may also include a 3-D model 210 of a real or computer-generated object. The 3-D model 210 contains all the necessary model information that is rendered by the 3-D application rendering module 212 to create the projection view image 108 .
The graphics API 204 is used by the 3-D application rendering module 212 to send the proper commands to the 3-D graphics accelerator 110 in order to create the projection view image 108 . In some applications, it may be preferable to store the projection view image 108 in the framebuffer 216 in order to display a visible object on a monitor (not shown) for the server 100 . The server 100 may also be used to transmit UI information for 2-D objects 214 through the windows/graphics protocol 206 to the windows API/X-server 304 at the client 102 . The 3-D rendering module 212 and 2-D objects 214 define the distributed application that resides on the server 100 .
The projection view image 108 may be scaled down by the 3-D graphics accelerator 110 . Scaling may include reducing the size of the projection view image 108 based on a dynamically selected sealing factor. The scaling factor used to scale down the projeclion view image 108 may be determined by the performance requiremats of a particular client or adaptively depending on the workflow in use. The scaling process is described in more detail with reference to FIG. 4 .
The windows/graphics protocol 206 may be used to open an application 3-D window 218 and display the scaled-down image 112 stored in the framebuffer 216 . The application 3-D window 218 may also contain windows information from the windows/graphics protocol 206 . Application 3-D window 218 and application rendering window 106 may be related to the extent that they perform similar functions and reside in the memory of the 3-D graphics accelerator 110 .
Application 3-D window 218 preferably includes memory from the framebuffer 216 . The memory from the framebuffer 216 , in some embodiments, refers to the visible memory of the 3-D graphics accelerator 110 that may be displayed on a monitor (not shown) at the server 100 .
Windows/graphics protocol 206 may also be used to open a window located at the client 102 . In addition, the application 3-D window 218 may be used to transmit information to the client 102 . In some embodiments, information from the application 3-D window 218 may be transmitted to the client 102 directly from the framebuffer 216 . The application 3-D window 218 may then be displayed at the client 102 in a window opened by windows API/X-server 304 once memory from the 3-D graphics accelerator 110 is mapped into the respective memory for the 3-D graphics accelerator 114 .
FIG. 3 is a block diagram of the client 102 in accordance with an embodiment of the invention. The client 102 may include an operating system 302 . The operating system 302 may include a windows API/X-Server 304 . The windows API/X-Server 304 may include a set of routines, protocols, or tools for managing display windows for various applications, such as an X windowing system or an X windowing emulator.
The client 102 may receive information from the server 100 . The information may be received by the windows API/X-Server 304 . The information received from the server 100 may include information that contains instructions or protocols to open one or more display windows, or to otherwise display data from the windows/graphics protocol 206 . The information received from the server 100 may also include scaled-down image 112 and/or other graphical information from the framebuffer 216 .
The information from the framebuffer 216 is transmitted to the 3-D graphics accelerator 114 , which is preferably used to render the scaled-up image 116 . The GPU for the 3-D graphics accelerator 114 may be used to perform bilinear interpolation, or other intended functions, to render the scaled-up image 116 . This process may also include the application of texture filters by the 3-D graphics accelerator 114 , which may result in a smoother, more continuous image.
The windows API/X-Server 304 may be used to open one or more windows in order to display the scaled-up image 116 and other data. For example, the API/X-server 304 may be used to open the application 3-D window(s) 310 that displays the scaled-up image 116 . Additionally, the API/X-server 304 may be used to open the user interface window 308 that displays UI information, such as text and other menu operational objects, and the application 2-D window(s) 312 that displays other 2-D images like color maps and other objects.
User interface window 308 , application 3-D window(s) 310 , and application 2D window(s) 312 are preferably part of the framebuffer 306 that may reside in the memory of the 3-D graphics accelerator 114 . In this embodiment, the user interface window 308 , application 3-D window(s) 310 , and application 2D window(s) 312 may be displayed on a display device (not shown) located at the client 102 . Application 3-D window(s) 310 and remote application rendering window 118 may be related to the extent that they perform similar functions and reside in the memory of the 3-D graphics accelerator 114 .
Referring now to FIG. 4 , a block diagram of the 3-D graphics accelerator 110 is shown in accordance with an embodiment of the invention. The results of the 3-D application rendering module 212 (i.e., the projection view image 108 ) may be stored in an array of discrete information units. Each of these discrete information units may be referred to as a component chunk. Each component chunk may comprise an array of values associated with color channel elements. For example, in one implementation, each component chunk includes values corresponding to the colors red, green, and blue (RGB) in any predetermined order. In another implementation, each component chunk may include values corresponding to the colors red, green, blue, and an opacity factor alpha (RGBA) in any predetermined order.
The 3-D graphics accelerator 110 may also include texture memory 404 , back buffer 406 , and a pixel transfer and mapping module 408 . The frame buffer 216 , texture memory 404 , and back buffer 406 , in one embodiment, exist in the memory of the 3-D graphics accelerator 110 . The texture memory 404 , also known as texture cache, may include specialized memory that is set aside for graphics operations. The component chunk information may be bound to the texture memory 404 , which may include loading and locking component chunk information into the texture memory 404 . The result may be referred to as a texture map. Binding the component chunk information to the texture memory 404 may also include converting the component chunk information into the native processing format of the server 100 , which may lead to faster processing performance inside the 3-D graphics accelerator 110 . This may be accomplished using a pixel transfer and mapping module 408 that is commonly found in most 3-D graphics cards. Because the 3-D graphics accelerator 110 is capable of reformatting the component chunk information to match the server's and client's native processing format, the CPU, the main memory, the bus bandwidth, and other computing system resources can be utilized for other processes or tasks.
The information contained in the texture memory 404 may be scaled and transferred to a visible back buffer 406 . A scaling factor may be selected or specified by a user or may be calculated or determined by a computer. The scaling factor may be specified or determined by the network bandwidth transmission requirements. This may depend on the performance requirements or workflows being used on a particular client 102 . For example, if a user requires a higher resolution, the scaling factor may be adaptively decreased, thereby increasing the amount of data transmitted until a desired resolution and performance are achieved. Alternatively, if a user is using a very slow bandwidth, the scaling factor may be increased, thereby reducing the amount of data transmitted until a desired resolution and interactive performance are achieved. The information contained in the texture memory 404 may also be scaled to a size that is proportional to the scaling factor. For example, in one embodiment, the information contained in the texture memory 404 may be scaled by a factor of 1/SF 2 , where SF is the scaling factor.
Thus, the information contained in the texture memory 404 (i.e., the texture map) may be scaled down by applying it to a polygon, such as a quadrilateral, having a scaling factor of 1/SF with respect to the projection view image 108 . The polygon is rendered directly into the back buffer 406 . As a result, all operations leading to the scaled-down image 112 may be performed exclusively within the 3-D graphics accelerator 110 , which enables the server resources to perform other tasks.
The scaled information in the back buffer 406 may be converted into a format that is more readily understood by a particular client 102 using the pixel transfer and mapping module 408 . The pixel transfer and mapping module 408 may thus, be used to reformat the scaled information received from the back buffer 406 , or framebuffer 216 , to match the format supported by the 3-D graphics accelerator 114 . This technique may include converting the scaled information into any well known format, including RGB or RGBA combinations. The scaled information that is converted in the manner thus described may be transmitted from the 3-D graphics accelerator 110 to one or more clients 102 through the network 104 .
Alternatively, the scaled information that is converted may be transmitted to a compression module 410 . The compression module 410 may be located on the server 100 , or elsewhere. The compression module 410 may apply additional compression techniques to the scaled information before it is transmitted to the client 102 via the network 104 . The compression module 410 may apply compression techniques such as JPEG, MPEG, RLE, LBX, fractal coding, wavelet compression, or other well known compression techniques.
In one embodiment of the invention, a user located at the server 100 or the client 102 may desire to interactively alter or manipulate the projection view 108 which may be done by using 2-D windowing and cursor information. The graphical information may also be manipulated automatically by the server 100 or the client 102 when, for example, the graphical information is updated. The graphical information may be displayed or imaged using lossy factors while it is being manipulated and it may be displayed using lossless factors when it is not being manipulated.
Referring now to FIG. 5 , a flow chart of a method for remotely displaying graphics depicts one embodiment of the invention. The method may begin at step 500 by rendering 3-D graphical information from a 3-D model 210 . Rendering 3-D graphical information in step 500 may include adding realism to computer graphics by adding three-dimensional attributes and qualities such as textures, lighting, shadows, and variations in color and shade. Rendering 3-D graphical information in step 500 may also include ray tracing, scanline rendering, or other well known rendering techniques.
Rendering 3-D graphical information may be performed, for example, by the 3-D application rendering module 212 . The 3-D application rendering module 212 may use the graphics API 204 as described in reference to FIG. 2 . Step 500 may produce any combination of 3-D information, 2-D information, and UI information.
In step 502 , the results of step 500 may be stored in the memory of the 3-D graphics accelerator 110 (i.e., the framebuffer 216 , texture memory 404 , back buffer 406 , or any other type of graphics card memory). The results stored during step 502 may be stored as component chunks and optionally displayed to a user at the server 100 . Each component chunk may be an array of values associated with color channel elements as described in reference to FIG. 4 .
Step 504 binds the results of step 500 into texture memory 404 . Step 504 may include loading and locking the results of step 500 into texture memory 404 . The results of step 504 may be referred to as a binded texture map. Step 504 may also include converting the results (texture map) into the native processing format of the server 100 as described in reference to FIG. 4 . This conversion technique may be accomplished using the pixel transfer and mapping module 408 , which may lead to faster processing performance inside the 3-D graphics accelerator 110 , and enable the CPU main memory, bus bandwidth and other system resources to be utilized for other tasks.
In step 506 , the result of step 504 may be scaled by selecting, specifying, or otherwise determining a scaling factor and rendering the scaled results to the memory for the 3-D graphics accelerator 110 in the manner described in reference to FIG. 4 . The scaling factor may be specified by a user or determined by a computer based on the network bandwidth reduction that is desired or necessary. This may depend on the performance requirements of a particular client 102 . For example, step 506 may include scaling the information contained in the texture memory 404 to a size that is proportional to the scaling factor. In one embodiment, this includes scaling the information contained in the texture memory 404 by a factor of 1/SF 2 , where SF is the scaling factor.
Step 508 converts the scaled results of step 506 into a format that is more readily understood by a particular client 102 . Step 508 may be performed also by using the pixel transfer and mapping module 408 . The pixel transfer and mapping module 408 may thus, be used to reformat the scaled results of step 506 to match the format supported by the 3-D graphics accelerator 114 for the client 102 as described in reference to FIG. 4 . This technique may include converting the scaled results of step 506 into any well known format, including RGB or RGBA combinations. The results of step 508 may be transmitted to one or more clients 102 via the network 104 .
Alternatively, the results of step 508 may be compressed in step 510 using a compression module 410 . Step 510 may be performed on the server 100 , or elsewhere. Step 510 may include applying additional compression techniques to the results of step 508 before being transmitted to the client 102 via the network 104 . Step 510 may include applying compression techniques such as JPEG, MPEG, RLE, LBX, fractal coding, wavelet compression, or other well known compression techniques.
Steps 504 , 506 , and 508 may be performed exclusively within the memory and processing units of the 3-D graphics accelerator 110 . As a result, the CPU, the main memory, the bus bandwidth, and other system resources may be used for other processes or tasks.
In one embodiment of the invention, a user located at the server 100 or the client 102 may desire to interactively alter or manipulate the graphical information rendered from the 3-D application rendering model 212 . The graphical information may also be manipulated automatically by the server 100 or the client 102 when, for example, the graphical information is updated. The graphical information may be displayed or imaged using lossy factors while it is being manipulated and it may be displayed using lossless factors when it is not being manipulated.
One or more display connections may be opened in step 512 . Step 512 may include an application running on the server 100 that can open one or more display connections to the remote windowing systems for a particular client 102 . Step 512 may therefore, be performed using the graphics API 204 and windows/graphics protocol 206 as described in reference to FIG. 2 . The empty client windows that are opened may be managed by a client window manager system.
In step 514 , protocols and information from the 3-D graphics accelerator 110 may be transmitted to the client 102 via the network 104 . Transmitting protocols may include transmitting windowing protocol, window managing protocol, or graphics protocol via the network 104 . In one embodiment, the client 102 may execute window system protocols and commands without running any client side processes or daemons. Transmitting information from the 3-D graphics accelerator 110 may include transmitting “raw” or unprocessed memory from the 3-D graphics accelerator 110 to the 3-D graphics accelerator 114 . Alternatively, information from the 3-D graphics accelerator 110 may be compressed, as described in reference to FIG. 4 , before it is transmitted to the client 102 .
In Step 516 , the information from the memory of the 3-D graphics accelerator 114 may be displayed to the client 102 on the opened windows using the transmitted protocols.
In summary, a single executable instance of an application comprising the 3-D application rendering module 212 and 2-D objects 214 may be located on the server 100 . The server 100 can therefore, remotely open various display connections as described in reference to step 512 . This allows the server 100 to write raw memory from the 3-D graphics accelerator 110 directly to multiple clients using different graphics memory resolutions and different scaling factors. This also allows the server 100 to control local and remote window refreshes so that windows are refreshed only as needed and only on the particular windows that need it. It may also allow the application to control security settings for specific windows or to use adaptive lossy or lossless compression for specific windows. Furthermore, the fact that rendering (step 500 ) need not be performed by the client 102 may reduce or eliminate many conventional system requirements for the client 102 .
FIGS. 6 a–f illustrate various optional networking environments in accordance with multiple embodiments of the invention. The computers illustrated in FIGS. 6 a–f may include desktop computers, laptop computers, dedicated servers, supercomputers, personal digital assistants (PDA's), other well known computing devices, or any combination thereof.
FIG. 6 a illustrates a local environment. The local environment may include locally running a server/client 600 . The server/client 600 may render and display 3-D graphical data.
FIG. 6 b illustrates a collaboration hub-networking environment. A collaboration hub may include any computer that transmits data to and receives data from multiple other computers. A collaboration hub may also be configured to incorporate changes received from multiple other computers into a single data object or other data instance. A collaboration hub may also control application security settings for one or more other computers. The collaboration hub networking environment may include a server/collaboration hub 602 , which may render and display 3-D graphical data as well as functioning as a collaboration hub. The collaboration hub networking environment may also include one or more collaboration clients 604 , 606 that remotely display 3-D graphical data that is rendered on the server/collaboration hub 602 . In one embodiment, the collaboration clients 604 , 606 may also alter or manipulate the rendered data. These changes may be tracked, processed, or stored by the server/collaboration hub 602 .
FIG. 6 c illustrates a remote execution networking environment. The remote execution networking environment may include a server 608 , which renders and displays 3-D graphical data. The remote execution networking environment may also include one or more clients 610 that remotely display 3-D graphical data rendered on the server 608 .
FIG. 6 d illustrates a remote execution and collaboration networking environment. The remote execution and collaboration networking environment may include a server 612 , which visibly or invisibly renders and displays 3-D graphical data. The remote execution and collaboration networking environment may also include one or more client/collaboration hubs 614 . Each client/collaboration hub 614 may remotely display 3-D graphical data that is rendered on the server 612 . Each client/collaboration hub 614 may transmit data to, and receive data from, one or more collaboration clients 616 , 618 . Each client/collaboration hub 614 may also be configured to incorporate changes received from collaboration clients 616 , 618 into a single data object or other data instance. The client/collaboration hub 614 may also control security settings for collaboration clients 616 , 618 . The collaboration clients 616 , 618 may remotely display 3-D graphical data that is rendered on the server 612 and transmitted via the client/collaboration hub 614 . In one embodiment, the collaboration clients 616 , 618 may also alter or manipulate the rendered data. These changes may be tracked, processed, or stored by each client/collaboration hub 614 through window and display state changes that are sent to the server 612 for processing and synchronization of all client interactions.
FIG. 6 e illustrates an application service provider (ASP) networking environment. The ASP networking environment may include one or more servers 620 , 622 , 624 , which render and display 3-D graphical data. The ASP networking environment may also include one or more client/ASP servers 626 . Each client/ASP server 626 may receive 3-D graphical data that is rendered on the servers 620 , 622 , 624 . Each client/ASP server 626 may include a computer that is configured to manage and distribute software-based services and solutions to customers across a wide area or other network from a central data center. In one embodiment, each client/ASP server 626 may be a third-party server that is owned or operated by an entity separate from the entity owning and operating the servers 620 , 622 , 624 or the client 628 . Each client/ASP server 626 may be an enterprise ASP, which is designed to deliver high-end business applications; a local or regional ASP, which is designed to supply a wide variety of application services for smaller businesses in a local area; a specialist ASP, which is designed to provide applications for a specific need; a vertical market ASP, which is designed to provide support to a specific industry; or a volume business ASP, which is designed to supply small or medium-sized businesses with prepackaged application services in volume. The ASP networking environment may also include one or more clients 628 that remotely display 3-D graphical data rendered on the servers 620 , 622 , 624 and transmit the 3-D graphical data to each client 628 via the client/ASP server 626 .
FIG. 6 f illustrates an ASP and collaboration networking environment. The ASP and collaboration networking environment may include one or more servers 630 , 632 , 634 , which render and display 3-D graphical data. The ASP and collaboration networking environment may also include one or more client/ASP servers 636 . Each client/ASP server 636 may receive 3-D graphical data that is rendered on the servers 630 , 632 , 634 . Each client/ASP server 636 may include a computer that is configured to manage and distribute software-based services and solutions to customers across a wide area or other network from a central data center. In one embodiment, each client/ASP server 636 may include a third-party server that is owned or operated by an entity separate from the entity owning and operating the servers 630 , 632 , 634 , the client/collaboration hub 638 , or the client 640 , 642 . Each client/ASP server 636 may be an enterprise ASP, which is designed to deliver high-end business applications; a local or regional ASP, which is designed to supply a wide variety of application services for smaller businesses in a local area; a specialist ASP, which is designed to provide applications for a specific need; a vertical market ASP, which is designed to provide support to a specific industry; or a volume business ASP, which is designed to supply small or medium-sized businesses with prepackaged application services in volume.
The ASP and collaboration networking environment may also include one or more client/collaboration hubs 638 . Each client/collaboration hub 638 may remotely display 3-D graphical data that is rendered on the servers 630 , 632 , 634 and is transmitted via the client/ASP server 636 . Each client/collaboration hub 638 may transmit data to and receive data from multiple clients 640 , 642 . The client/collaboration hub 638 may be configured to incorporate changes received from clients 640 , 642 into a single data object or other data instance. Each client/collaboration hub 638 may also control security settings for the clients 640 , 642 . The clients 640 , 642 may also remotely display 3-D graphical data that is rendered on the servers 630 , 632 , 634 , and transmitted via the client/ASP server 636 and the client/collaboration hub 638 . In another embodiment, the collaboration clients 640 , 642 may also alter or manipulate the rendered data through window and display state changes that are sent to the servers 630 , 632 , 634 for processing and synchronization of all client interactions.
The foregoing description of the invention is illustrative, and modifications in configuration and implementation will occur to persons skilled in the art. For instance, steps can be combined or may be performed in any order. Hardware, software or other resources described as singular may in embodiments be distributed, and similarly in embodiments resources described as distributed may be combined. The scope of the invention is accordingly intended to be limited only by the following claims. | Systems and methods for network transmission of three-dimensional graphical data are disclosed. A single graphical application instance can virtually and efficiently exist on multiple local or remote display systems by directly sharing its raw rendered framebuffer memory information among all local or remote graphics accelerators, thus avoiding the need to re-render any application information again on each node. An internal graphics card is used to scale the rendered data prior to transmission. This graphics scaling eliminates the need for data compression or image compression and achieves an adaptive, hardware-accelerated reduction in network bandwidth. Furthermore, since all memory and remote processing support tasks are performed within the graphics card, the CPU, system bus, and memory bandwidth remain available to the system and other applications. | 7 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/027,620, filed Oct. 4, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to subsurface well drilling equipment and, more particularly, to apparatus for connecting and disconnecting components of a bottom hole assembly to a tubing, but preferably coiled tubing, and for connecting and disconnecting components to other components of the bottom hole assembly.
2. Description of the Related Art
A Bottom Hole Assembly (commonly referred to in the industry as a BHA) for drilling wells with a coiled tubing comprises various constituent parts which may include: a drill bit, a bent sub for changing the vertical angle of penetration, a motor for rotating the bit, a circulating sub for flowing drilling mud to prevent sticking of the BHA in the well, an orienting tool for changing the direction of penetration, a thruster for providing weight on the bit, and a sub which provides a means for selectively attaching and releasing the BHA from the coiled tubing. The present invention is directed to a device which is a significant improvement over the prior art for selectively attaching and releasing the BHA from the coiled tubing.
While drilling wells, it is possible for the BHA to become lodged downhole due to differential pressure that may exist in the well and/or a cave-in of the hole, or excessive friction due to well trajectory. Coiled tubing has a relatively smaller wall thickness than conventional drill pipe, and therefore has a reduced tensile strength, and therefore a reduced capacity to pull a lodged BHA from a well. This is especially true if a portion of the well has been drilled horizontally. If the tensile strength of the coiled tubing is exceeded while attempting to pull the BHA from the well, tensile failure can occur, resulting in an unpredictable parting of the tubing. The presence of an unpredictable length and configuration of coiled tubing left in the well with the lodged BHA makes retrieval difficult, if not impossible, and can result in the loss of the expensive BHA and the possible abandonment of the well. Prior art references are as follows, all of which are U.S. Pat. Nos. 5,323,853; 4,476,945; 4,913,229; 5,265,675.
There is a need for a device to allow coiled tubing to be easily pulled from or attached to the connector on a first end, and on a second end, have a connector that may quickly and easily be removed from and attached to the BHA.
SUMMARY OF THE INVENTION
The present invention has been contemplated to overcome the foregoing deficiencies and meet the above described needs.
The invention is an Emergency Release Tool that connects a coiled tubing to a Bottom Hole Assembly (BHA) and is electrically activated upon a signal from the surface. The electrical signal may ignite a propellant, or release gas, or it may activate a downhole hydraulic or gaseous fluid source, or actuate a solenoid, motor, or heating coil to enable the release of the coiled tubing from the Emergency Release Tool. Other well known methods of applying fluidic pressure to operate a downhole tool may also be employed and still be within the scope and spirit of the present invention. In the preferred embodiment, activation of the fluidic pressure release means causes the mechanism described in the attached drawings to release the coiled tubing, such that it pulls free of the Emergency Release Tool in a completely non-destructive manner, as well as enabling removal of any additional restraints, such as an electric line. The release of only the tubing leaves no enlarged or "upset" areas attached to the tubing which can interfere with the removal of the tubing from the well. The Emergency Release Tool leaves at least one profile (commonly known as a fishing profile) upon which a robust pulling tool can be engaged, greatly enhancing the possibility that the lodged BHA can be removed from the well. On the lower end of the Emergency Release Tool, a quick disconnect has been developed to enable quick and easy attachment to the BHA. This quick disconnect operates by insertion of a pin (or male) connection inside of a box (or female) connection, the locking of which is accomplished by a fractional portion of one full rotation. Fluidic seal of the two halves is accomplished by an o-ring, packing, metal seal, or other well known means.
When attaching the Emergency Release Tool to tubing, only deburring of the tubing is necessary for installation. This allows simple and cost effective field assembly to be completed quickly at any time. The device may be easily removed from the coiled tubing without the need for redress, or with minor redress, before being reattached. When remotely activated, the fluidic pressure release means shifts a sleeve to relieve pressure on a slip which anchors the device to the coil. The expanding gas pressure continues to transmit force to unseat the slips and their restraints. Movement of the sleeve mechanically releases an electric line or "E-line" (or other conduit inside the coiled tubing) and separates the slips from a loading nut to prevent the slips from re-engaging. The tubing and "E-line" slide from the Emergency Release Tool leaving only the OD of the tubing, continuous to the surface, to be removed from the hole. The fishing profile would simultaneously be revealed to allow later retrieval of the lodged tool, if desired. In the event of lodged or damaged tubing, the "E-line" may be pulled from the device and the tubing may be retrieved by conventional well retrieval methods.
The Emergency Release is connected to the rest of the tool string by way of a locking "Quick Connect." This connection allows minimal rotation of parts being assembled, eases and quickens repair or replacement of components, and provides a universal profile to simplify custom configurations. A series of lugs on the pin portion are positioned in recesses in the box portion and then are held in place by a rigid spacer which transmits compressive loads through the connection. The lugs transmit all tensile and torque forces through the connection and the integral sealing means in the body of the connector maintain a fluidic pressure seal under the harsh conditions that exist when drilling with coiled tubing. This connection can be used with most of the components of the BHA as well as the Emergency Release Tool. This enables a beneficial modularity whereby specific devices may be added, removed, or changed in relative position in the BHA.
One skilled in the art of coiled tubing drilling will immediately appreciate the benefits of the Emergency Release Tool of the present invention, since: it leaves a smooth OD for highest probability of coil extraction; attachment to the tubing requires no machining or preparation of tubing other than deburring; the tool is activated remotely when desired; it does not rely on any external forces being applied to the device; it will operate without moving the tubing or the attached tools; it also reveals a robust fishing neck for alternate retrieval methods of the conveyed tool; it can be used with "E-line," control line, umbilical, etc., installed in the tubing; a redundant "E-line" disconnect allows conventional extraction of "E-line" if tubing is still lodged or damaged allowing conventional coiled tubing recovery; and the tool has a proven "Quick Connect" profile for convenience and modularity.
In one aspect, the invention includes an emergency release tool comprising: a releasable slip for holding a coiled tubing, the releasable slip being secured to a first end of a slip case, the slip case being disposed within a slip housing and a lower housing, the slip housing being movable from a locked position to a released position; a piston slidably disposed about the slip case and being moveable from a locked position to a released position; a first end of the lower housing being releasably connected to a second end of the slip housing when the slip housing is in its locked position; and, a remotely activated means for moving the piston and the slip housing from their locked positions to their released positions to disengage the releasable slip from the coiled tubing and enable the coiled tubing to be removed from the tool. Another feature of this aspect of the invention is that the tool may further include a loading nut movably secured to a first end of the slip housing and mating with the releasable slip for holding the coiled tubing. Another feature of this aspect of the invention is that the loading nut may be threadably secured to the first end of the slip housing. Another feature of this aspect of the invention is that the loading nut may include a flared portion for mating with a flared portion on the releasable slip. Another feature of this aspect of the invention is that the flared portions on the loading nut and on the slip may be flared at angles of approximately three degrees. Another feature of this aspect of the invention is that the loading nut may include a fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool. Another feature of this aspect of the invention is that the second end of the slip housing may further include at least one dog and is telescopically received within the first end of the lower housing, the piston holding the at least one dog in an annular recess in the first end of the lower housing when the piston is in its locked position to connect the slip housing to the lower housing, and the piston releasing the at least one dog to disconnect the slip housing and the lower housing and moving the slip housing to its released position when the piston is moved from its locked position to its released position. Another feature of this aspect of the invention is that the annular recess in the lower housing may function as a redundant fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool and upon detachment from the tool of the releasable slip, the slip case, the slip housing, and the piston. Another feature of this aspect of the invention is that the lower housing may further include an annular load bearing shoulder that may function as a redundant fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool and upon detachment from the tool of the releasable slip, the slip case, the slip housing, and the piston. Another feature of this aspect of the invention is that the slip case may include an outer surface having a shoulder and at least one recess for housing at least one locking dog, the at least one locking dog being in a compressed position when the slip housing is in its locked position, and the at least one locking dog being moveable to engage an annular recess within the slip housing when the slip housing is in its released position. Another feature of this aspect of the invention is that the piston may be releasably secured to the lower housing when the piston is in its locked position. Another feature of this aspect of the invention is that the tool may further include a collet being releasably connected to the piston and to the lower housing, the collet being released from the piston when the piston is shifted from its locked position to its released position. Another feature of this aspect of the invention is that the collet may include a plurality of fingers having threaded portions at distal ends thereof for mating with a threaded portion on the lower housing to releasably secure the collet to the lower housing. Another feature of this aspect of the invention is that the collet may be releasably secured to the piston by a shear pin. Another feature of this aspect of the invention is that the slip case may further include a locking shoulder for loading the distal ends of the collet fingers when a well tool is being used to engage a fishing profile on the tool to retrieve the tool and an attached bottom hole assembly. Another feature of this aspect of the invention is that the remotely activated means may include a propellant that, when ignited, forces the piston and the slip housing from their locked positions to their released positions. Another feature of this aspect of the invention is that the propellant may be disposed about the slip case and beneath the piston, and may be remotely ignited by an electrical signal. Another feature of this aspect of the invention is that the remotely activated means may include a gas that, when released, forces the piston and the slip housing from their locked positions to their released positions. Another feature of this aspect of the invention is that the remotely activated means may include a heating coil, when energized, forces the piston and the slip housing from their locked positions to their released positions. Another feature of this aspect of the invention is that the remotely activated means may include an electrically actuated valve for controlling the interaction of a compressed gas source with the piston to force the piston and the slip housing from their locked positions to their released positions. Another feature of this aspect of the invention is that the remotely activated means may include an electrically actuated valve for controlling the interaction of a hydraulic fluid source with the piston to force the piston and the slip housing from their locked positions to their released positions. Another feature of this aspect of the invention is that the remotely activated means may be connected to and activated by a conductor cable running through the coiled tubing from the earth's surface to the tool. Another feature of this aspect of the invention is that the conductor cable may be remotely detached from the emergency release tool and removed from the coiled tubing so that conventional well tools may be used to remove the emergency release tool and a bottom hole assembly attached thereto from the well. Another feature of this aspect of the invention is that the tool may further include means for sealing individual conductors within the conductor cable from drilling fluid being circulated through the tool.
Another feature of this aspect of the invention is that the conductor sealing means may include: an anchor, an armor nut, a conductor cable sealing connector, and a flow tube; the anchor being received within the coiled tubing and removably connected to the armor nut; the anchor and the armor nut having cooperating inclined surfaces for holding an armor portion of the conductor cable; the conductor cable sealing connector having a plurality of longitudinal bores extending therethrough and including a carrier plug, a composite seal, and a follower plug, the composite seal being disposed between the carrier plug and the follower plug, and each of the individual conductors passing through one of the plurality of longitudinal bores; and, a first end of the flow tube being connected to the armor nut to compress the sealing connector between a shoulder on the flow tube and a shoulder on the armor nut and to compress the composite seal and seal the individual conductors from the drilling fluid, and a second end of the flow tube being received within a longitudinal bore of the inner mandrel. Another feature of this aspect of the invention is that the conductor cable may be remotely detached from the tool by shearing the armor from between the anchor and the armor nut and removed from the coiled tubing so that conventional well tools may be used to remove the emergency release tool and a bottom hole assembly attached thereto from the well. Another feature of this aspect of the invention is that the piston includes a shoulder disposed beneath an aperture in the slip housing, whereby well bore pressure is applied through the aperture to the piston shoulder to maintain a downward force on the piston to counteract any upward forces on the piston that may develop during the drilling process, other than forces generated as a result of the activation of the remotely activated means. Another feature of this aspect of the invention is that the tool releases the coiled tubing in a nondestructive manner so as to leave no enlarged diameters on the tubing that could interfere with removal of the coiled tubing from a well. Another feature of this aspect of the invention is that, upon activation of the remotely activated means to disengage the coiled tubing from the tool, no part of a conductor sealing means within the tool is larger than an outer diameter of the coiled tubing, so that removal of the conductor sealing means from the tool will not interfere with removal of the coiled tubing from a well. Another feature of this aspect of the invention is that the coiled tubing is released from the tool solely by remote activation of the remotely activated means without mechanical manipulation of the emergency release tool by a well tool. Another feature of this aspect of the invention is that the coiled tubing is released from the tool solely by remote activation of the remotely activated means without movement of the coiled tubing. Another feature of this aspect of the invention is that the coiled tubing is released from the tool solely by remote activation of the remotely activated means without movement of a bottom hole assembly connected to the emergency release tool. Another feature of this aspect of the invention is that the coiled tubing need only be deburred to be installed adjacent the releasable slip. Another feature of this aspect of the invention is that the tool may further include a quick disconnect coupler attached to a second end of the lower housing, the quick disconnect coupler including a pin connector having a series of lugs, a box connector for receiving the pin connector and having a series of recesses to engage and hold the lugs, a rigid spacer between the box and pin connectors for transmitting operating loads through the connection, and an integral sealing means for maintaining a fluidic pressure seal between the pin and box connectors.
In another aspect, the emergency release tool may comprise: a loading nut having a longitudinal bore extending therethrough, a first end, and a second end having an outer surface, the longitudinal bore having a flared portion at the second end of the loading nut, and the outer surface of the second end having a threaded portion; a slip housing having a longitudinal bore extending therethrough, a first end, and second end, the longitudinal bore having a threaded portion at the first end of the slip housing for mating with the threaded portion on the loading nut and an annular recess forming a shoulder, and the second end of the slip housing having at least one dog; a lower housing having a longitudinal bore extending therethrough, a first end, and second end, the second end of the slip housing being telescopically received within the longitudinal bore of the lower housing at the first end thereof, and an annular recess at the first end of the lower housing for receiving the at least one dog in the second end of the slip housing; a slip case having a longitudinal bore extending therethrough, a first end, a second end, and an outer surface, the outer surface having a shoulder and at least one recess, the at least one recess housing at least one locking dog; at least one slip connected to the first end of the slip case and having a flared end for mating with the flared end of the loading nut and an inner surface, the inner surface having gripping teeth for gripping a coiled tubing; a piston disposed for longitudinal movement around the slip case and being releasably secured to the lower housing when the tool is in a locked position, the at least one dog in the second end of the slip housing being held within the annular recess in the lower housing by the piston when the tool is in the locked position, the piston being movable to release the at least one dog from the annular recess when the tool is being shifted from its locked position to a released position; and a remotely activated means for moving the tool from its locked position to its released position to disengage the at least one slip from the coiled tubing.
Another feature of this aspect of the present invention is that the tool may further include a collet being releasably connected to the piston and to the lower housing, the collet being released from the piston when the tool is shifted from its locked position to its released position. Another feature of this aspect of the present invention is that the collet may be releasably secured to the piston by at least one shear pin. Another feature of this aspect of the present invention is that the collet may further include a body portion having a plurality of fingers depending therefrom, the fingers having distal ends, the distal ends having a threaded portion engaged with a threaded portion in the longitudinal bore of the lower housing. Another feature of this aspect of the present invention is that the collet may be disposed around a second extension of the piston and within the longitudinal bore of the lower housing, and the collet body is releasably secured to the second extension of the piston. Another feature of this aspect of the present invention is that the remotely activated means may include a gas that, when released, moves the tool from its locked position to its released position. Another feature of this aspect of the present invention is that the remotely activated means may include a heating coil, when energized, moves the tool from its locked position to its released position. Another feature of this aspect of the present invention is that the remotely activated means may include an electrically actuated valve for controlling the interaction of a compressed gas source with the piston to move the tool from its locked position to its released position. Another feature of this aspect of the present invention is that the remotely activated means may include an electrically actuated valve for controlling the interaction of a hydraulic fluid source with the piston to move the tool from its locked position to its released position. Another feature of this aspect of the present invention is that the remotely activated means may include a propellant that, when ignited, moves the tool from its locked position to its released position. Another feature of this aspect of the present invention is that the propellant may be disposed about the slip case and beneath the piston, and is remotely ignited by an electrical signal.
Another feature of this aspect of the present invention is that the tool may further include: a charge mandrel having a main body portion and a first extension, the charge mandrel being connected to the second end of the slip case and disposed within the longitudinal bore of the lower housing, the first extension having a distal end and a propellant retaining shoulder, the main body portion having a loading shoulder for bearing against an annular load bearing shoulder in the longitudinal bore of the lower housing; and, a propellant retainer ring having an outer surface, a first edge, and a second edge, the retainer ring being movably connected to the distal end of the first extension of the charge mandrel, the propellant being disposed between the longitudinal bore of the lower housing and an outer surface of the first extension of the charge mandrel, and being held in place between the second edge of the ring and the retaining shoulder on the charge mandrel when the tool is in its locked position. Another feature of this aspect of the present invention is that the outer surface of the propellant retainer ring includes at least one recess to facilitate the passage of gases generated upon ignition of the propellant. Another feature of this aspect of the present invention is that the tool may further include: a collet being releasably connected to the piston and to the lower housing, the collet being released from the piston when the tool is shifted from its locked position to its released position, the collet having a body portion having a plurality of fingers depending therefrom, the fingers having distal ends, the distal ends having a threaded portion engaged with a threaded portion in the longitudinal bore of the lower housing; and, a locking shoulder on the outer surface of the propellant retainer ring adjacent a first edge thereof, the locking shoulder loading the distal ends of the collet fingers when a well tool is being used to engage a fishing profile on the tool to retrieve the tool and an attached bottom hole assembly.
Another feature of this aspect of the present invention is that the longitudinal bore of the loading nut may further include a fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool, the forces imparted to the fishing profile by the well tool being transferred to the bottom hole assembly through the shoulder on the slip housing that is bearing against the shoulder on the slip case, through the locking shoulder on the propellant retainer ring that is bearing against the distal ends of the collet fingers, and through the threaded portions on the collet fingers that are threadably engaged with the threaded portion on the lower housing, the threaded portions on the collet fingers and the lower housing being designed to fail at a preselected load, whereby, upon the preselected load being exceeded, the collet being disengaged from the lower housing, and the tool, except for the lower housing, being disengaged from the bottom hole assembly. Another feature of this aspect of the present invention is that the main body portion of the charge mandrel may include an electrical conductor conduit for receiving an individual conductor of a conductor cable. Another feature of this aspect of the present invention is that the main body portion may further include a connector disposed in the electrical conductor conduit for connecting an individual conductor of a conductor cable to a conductor connected to the propellant. Another feature of this aspect of the present invention is that the tool may further include an extension connected to a lower end of the charge mandrel for sealably receiving an upper portion of an uppermost tool in a bottom hole assembly. Another feature of this aspect of the present invention is that the piston may include a first extension, a second extension, and a first shoulder adjacent the first extension, the first extension being disposed for longitudinal movement within the longitudinal bore of the slip housing and having an area of increased diameter and an area of reduced diameter, the second extension being disposed for longitudinal movement within the longitudinal bore of the lower housing, the at least one dog in the second end of the slip housing being held within the annular recess in the lower housing by the area of increased diameter on the first extension of the piston when the tool is in its locked position, and the piston being movable to release the at least one dog from the annular recess when the tool is being shifted from its locked position to its released position.
Another feature of this aspect of the present invention is that the flared portions on the loading nut and on the slip may be flared at angles of approximately three degrees. Another feature of this aspect of the present invention is that the second end of the slip housing may include at least one notch for engaging at least one prong on the first end of the lower housing. Another feature of this aspect of the present invention is that the at least one slip may include a T-shaped end for mating with a corresponding T-shaped slot in the first end of the slip case. Another feature of this aspect of the present invention is that the at least one locking dog housed in the slip case may be springloaded. Another feature of this aspect of the present invention is that the piston may include a shoulder disposed beneath an aperture in the slip housing, whereby well bore pressure is applied through the aperture to the piston shoulder to maintain a downward force on the piston to counteract any upward forces on the piston that may develop during the drilling process, other than forces generated as a result of the activation of the remotely activated means. Another feature of this aspect of the present invention is that, when the tool is shifted from a locked position to a released position, the shoulder on the slip case engages the shoulder on the slip housing and the locking dogs move outwardly to engage the annular recess in the slip housing. Another feature of this aspect of the present invention is that the remotely activated means may be connected to and activated by a conductor cable running through the coiled tubing from the earth's surface to the tool. Another feature of this aspect of the present invention is that the conductor cable may be remotely detached from the emergency release tool and removed from the coiled tubing so that conventional well tools may be used to remove the emergency release tool and a bottom hole assembly attached thereto from the well.
Another feature of this aspect of the present invention is that the tool may further include means for sealing individual conductors within the conductor cable from drilling fluid being circulated through the tool. Another feature of this aspect of the present invention is that the conductor sealing means may include: an anchor, an armor nut, a conductor cable sealing connector, and a flow tube; the anchor being received within the coiled tubing and removably connected to the armor nut; the anchor and the armor nut having cooperating inclined surfaces for holding an armor portion of the conductor cable; the conductor cable sealing connector having a plurality of longitudinal bores extending therethrough and including a carrier plug, a composite seal, and a follower plug, the composite seal being disposed between the carrier plug and the follower plug, and each of the individual conductors passing through one of the plurality of longitudinal bores; and, a first end of the flow tube being connected to the armor nut to compress the sealing connector between a shoulder on the flow tube and a shoulder on the armor nut and to compress the composite seal and seal the individual conductors from the drilling fluid, and a second end of the flow tube being received within a longitudinal bore of the inner mandrel. Another feature of this aspect of the present invention is that the conductor cable may be remotely detached from the tool by shearing the armor from between the anchor and the armor nut and removed from the coiled tubing so that conventional well tools may be used to remove the emergency release tool and a bottom hole assembly attached thereto from the well. Another feature of this aspect of the present invention is that the tool releases the coiled tubing in a nondestructive manner so as to leave no enlarged diameters on the tubing that could interfere with removal of the coiled tubing from a well. Another feature of this aspect of the present invention is that, upon activation of the remotely activated means to disengage the coiled tubing from the tool, no part of a conductor sealing means within the tool is larger than an outer diameter of the coiled tubing, so that removal of the conductor sealing means from the tool will not interfere with removal of the coiled tubing from a well. Another feature of this aspect of the present invention is that the coiled tubing may be released from the tool solely by remote activation of the remotely activated means without mechanical manipulation of the emergency release tool by a well tool. Another feature of this aspect of the present invention is that the coiled tubing may be released from the tool solely by remote activation of the remotely activated means without movement of the coiled tubing. Another feature of this aspect of the present invention is that the coiled tubing may be released from the tool solely by remote activation of the remotely activated means without movement of a bottom hole assembly connected to the emergency release tool. Another feature of this aspect of the present invention is that the coiled tubing need only be deburred to be installed adjacent the releasable slip. Another feature of this aspect of the present invention is that the annular recess in the lower housing may function as a redundant fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool and upon detachment of the lower housing from the remainder of the emergency release tool. Another feature of this aspect of the present invention is that the lower housing may further include an annular load bearing shoulder that may function as a redundant fishing profile for engaging a well tool to be used in retrieving the emergency release tool and a bottom hole assembly attached thereto upon the coiled tubing being released from the emergency release tool and upon detachment of the lower housing from the remainder of the emergency release tool. Another feature of this aspect of the present invention is that a quick disconnect coupler may be attached to a second end of the lower housing, the quick disconnect coupler including a pin connector having a series of lugs, a box connector for receiving the pin connector and having a series of recesses to engage and hold the lugs, a rigid spacer between the box and pin connectors for transmitting operating loads through the connection, and an integral sealing means for maintaining a fluidic pressure seal between the pin and box connectors.
Another aspect of the present invention may include a quick disconnect coupler. In one aspect, the quick disconnect coupler may include: a pin connector having a series of lugs; a box connector for receiving the pin connector and having a series of recesses to engage and hold the lugs inside the box connector; and, a load ring between the box connector and the pin connector for transmitting compressive loads through the connection. Another feature of this aspect of the present invention is that the quick disconnect coupler may further include an integral sealing means for maintaining a fluidic pressure seal between the pin connector and the box connector. Another feature of this aspect of the present invention is that the box connector and the pin connector may be alternately locked and unlocked by relative rotation of the box and pin connectors, where said rotation is a fraction of a full 360 degree turn.
In another aspect, the quick disconnect coupler may include: a box connector having a longitudinal bore extending therethrough, the longitudinal bore having a plurality of ribs at a first end of the box connector and a plurality of grooves defined between the ribs, each rib having a recess disposed therein; a pin connector having a shoulder adjacent a main body portion and a pin member, the pin member having a plurality of lugs for mating with the recesses in the ribs on the box connector; and, a load ring removably positionable between the shoulder on the pin connector and the first end of the box connector. Another feature of this aspect of the present invention is that the plurality of ribs may be evenly spaced about the circumference of the longitudinal bore of the box connector. Another feature of this aspect of the present invention is that the recess in each rib may be disposed between a first leg and second leg on the rib. Another feature of this aspect of the present invention is that a distal end of each second leg may be located closer to the first end of the box connector than is a distal end of each first leg. Another feature of this aspect of the present invention is that the pin member may further include at least one seal groove for receiving a sealing ring to establish a fluidic pressure seal between the pin connector and box connector. Another feature of this aspect of the present invention is that the coupler may further include a load ring retainer for fastening the load ring between the pin connector and the box connector.
In another aspect, the present invention encompasses a method of using a quick disconnect coupler for connecting a first and a second device, the quick disconnect coupler including a box connector having a longitudinal bore extending therethrough, the longitudinal bore having a plurality of ribs at a first end of the box connector and a plurality of grooves defined between the ribs, each rib having a recess disposed therein, a pin connector having a shoulder adjacent a main body portion and a pin member, the pin member having a plurality of lugs for mating with the recesses in the ribs on the box connector, and a load ring removably positionable between the shoulder on the pin connector and the first end of the box connector, the method comprising the steps of: connecting a second end the box connector to the first device; connecting an end of the pin connector opposite the shoulder to the second device; sliding the lugs on the pin connector into the grooves on the box connector until the shoulder on the pin connector abuts against the first end of the box connector; rotating the pin connector a fraction of a full 360 degree turn until the lugs are positioned adjacent their corresponding recesses; sliding the lugs into their corresponding recesses; and, fastening the load ring around the pin member, and between the shoulder on the pin connector and the first end of the box connector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1E illustrate a longitudinal cross-sectional view of a full assembly of an emergency release tool of the present invention.
FIG. 2 is a longitudinal cross section of an assembly of a quick disconnect coupler of the present invention.
FIG. 3 is a longitudinal cross-sectional view of a box or female end of the quick disconnect coupler shown in FIG. 2.
FIG. 4 is cross-sectional view of the box or female end of the quick disconnect coupler taken along line 4--4 of FIG. 3.
FIG. 5 is a longitudinal view of a pin or male end of the quick disconnect coupler shown in FIG. 2.
FIG. 6 is a partial elevation view of the emergency release tool, taken along line 6--6 of FIG. 1A, with a portion of the tool removed to illustrate a T-shaped interconnection of a first slip and a slip case.
FIG. 7 is a partial elevation view of the emergency release tool illustrating interlocking components, taken along line 7--7 of FIG. 1C.
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 1B.
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 1D.
FIGS. 10A-10E illustrate a longitudinal cross-sectional view of the assembly illustrated in FIGS. 1A-1E in a released position.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
In the description which follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The figures are not necessarily drawn to scale, and in some instances, have been exaggerated or simplified to clarify certain features of the invention. One skilled in the art will appreciate many differing applications of the described apparatus.
For the purposes of this discussion, the terms "upper" and "lower", "up hole" and "downhole", and "upwardly" and "downwardly" are relative terms to indicate position and direction of movement in easily recognized terms. Usually, these terms are relative to a line drawn from an upmost position at the surface to a point at the center of the earth, and would be appropriate for use in relatively straight, vertical wellbores. However, when the wellbore is highly deviated, such as from about 60 degrees from vertical, or horizontal these terms do not make sense and therefore should not be taken as limitations. These terms are only used for ease of understanding as an indication of what the position or movement would be if taken within a vertical wellbore.
FIGS. 1A-1E, taken together, illustrate a longitudinal view of an emergency release tool of the present invention in a locked position and connected to a coiled tubing 11. In a specific embodiment, the emergency release tool 10 includes a loading nut 12, a slip housing 14, a lower housing 16, a first slip 18a, a second slip 18b, a slip case 20, a piston 22, a collet 24, a propellant retainer ring 26, a propellant 28, a charge mandrel 30, an extension 32, an anchor 34, an armor nut 36, a conductor cable sealing connector 38, and a flow tube 40. In a specific embodiment, the slips 18a and 18b, the slip case 20, the charge mandrel 30, the propellant retainer ring 26, and the extension 32 may be provided as an integral component, and may be referred to as an inner mandrel. In another specific embodiment, the tool 10 may be provided without the extension 32. In another specific embodiment, the tool 10 may be provided without the anchor 34, the armor nut 36, the conductor cable sealing connector 38, and the flow tube 40, which components are sometimes referred to below as a sealing assembly.
The loading nut 12 includes a longitudinal bore 42 extending therethrough, a first end 44, and a second end 46. The longitudinal bore 42 includes a fishing profile 48, the purpose of which will be explained below. The longitudinal bore 42 at the second end 46 of the loading nut 12 includes a flared portion 50. In a specific embodiment, the flared portion 50 is outwardly flared at approximately a 3-degree angle. An outer surface 52 of the second end 46 of the loading nut 12 is stepped radially inwardly from an outer surface 54 of the first end 44 of the loading nut 12 to form a shoulder 56. The outer surface 52 of the second end 46 of the loading nut 12 includes a threaded portion 58.
The slip housing 14 includes a longitudinal bore 60 extending therethrough, a first end 62, and second end 64. The longitudinal bore 60 includes a threaded portion 66 at the first end 62 of the slip housing 14 for mating with the threaded portion 58 on the loading nut 12. The longitudinal bore 60 also includes an annular recess 68 (FIG. 1B) adjacent a shoulder 69, the functions of which will be explained below. An outer surface 70 (FIG. 1C) of the second end 64 of the slip housing 14 is stepped radially inwardly from an outer surface 72 of the first end 62 of the slip housing 14 to form a shoulder 74. The second end 64 of the slip housing 14 includes at least one dog 76, the function and operation of which will be explained below. In a specific embodiment, the slip housing 14 may include four dogs 76. As best shown in FIG. 7, the second end 64 of the slip housing 14 is also provided with a first notch 78 adjacent the shoulder 74. Referring back to FIG. 1C, the slip housing 14 may be provided with a second notch 80 on the opposite side of the slip housing 14 from the first notch 78. The purpose of the notches 78 and 80 will be explained below. The slip housing 14 may also include an aperture 81 above the shoulder 74, the function of which will be explained below.
The lower housing 16 includes a longitudinal bore 82 extending therethrough, a first end 84, and second end 86. As best shown in FIG. 7, the first end 84 of the lower housing 16 is provided with first and second prongs 88 and 90 for mating with the first and second notches 78 and 80 on the second end 64 of the slip housing 14. The second end 64 of the slip housing 14 is telescopically received, at the first end 84 of the lower housing 16, within the longitudinal bore 82 of the lower housing 16. The longitudinal bore 82 includes an annular recess 92 at the first end 84 of the lower housing 16 for receiving the at least one dog 76 in the second end 64 of the slip housing 14, as will be more fully explained below. The longitudinal bore 82 of the lower housing 16 also includes a threaded portion 94, and an annular shoulder 96 (FIG. 1D) at the second end 86 of the lower housing 16, the functions of which will be explained below. The lower housing 16 may also be provided with a quick disconnect profile, as will be discussed more fully below.
Referring to FIG. 1A, the slips 18a and 18b include inner surfaces 98a and 98b, flared ends 100a and 100b, and T-shaped ends 102a (FIG. 6) and 102b. The flared ends 100a and 100b mate with the flared portion 50 of the loading nut 12. In a specific embodiment, the flared ends 100a and 100b may be inwardly flared at approximately 3-degree angles. The inner surfaces 98a and 98b of the flared ends 100a and 100b include gripping teeth 104a and 104b for gripping the coiled tubing 11.
The slip case 20 includes a longitudinal bore 108 extending therethrough, a first end 110, a second end 112, and an outer surface 114. As shown in FIG. 6, the first end 110 includes T-shaped slots 116a and 116b for receiving the T-shaped ends 102a and 102b, respectively, of the slips 18a and 18b. The outer surface 114 of the slip case 20 includes a shoulder 115 (FIG. 1B) and first and second recesses 118a and 118b, disposed adjacent the shoulder 115, for receiving first and second spring-loaded locking dogs 120a and 120b. The locking dogs 120a and 120b are shown in a compressed state, but, when the tool 10 is shifted to its released position--not shown, but to be more fully explained below--the shoulder 115 on the slip case 20 engages the shoulder 69 on the slip housing 14, and the locking dogs 120a and 120b move radially outwardly under the force of springs 122a and 122b to engage the annular recess 68 in the slip housing 14. As shown in FIG. 1D, the outer surface 114 adjacent the second end 112 of the slip case 20 includes a threaded portion 122, the function of which will be explained below.
Referring to FIG. 1C, the piston 22 is disposed for longitudinal movement around the slip case 20 and within the longitudinal bore 82 of the lower housing 16. The piston 22 includes a first extension 124, a second extension 126, and a first shoulder 127 adjacent the first extension 124. The first extension 124 is disposed for longitudinal movement around the slip case 20 and within the longitudinal bore 60 of the slip housing 14, and includes an inclined surface 128 connecting an area of increased diameter 129, an area of reduced diameter 130, and a shoulder 131 disposed beneath the aperture 81 in the slip housing 14. Well bore pressure is applied through the aperture 81 to the shoulder 131 to maintain a downward force on the piston 22 to counteract any upward forces on the piston 22--other than the forces generated as a result of the ignition of the propellant 28--that may develop during the drilling process. The second extension 126 is disposed for longitudinal movement around the slip case 20 and within the longitudinal bore 82 of the lower housing 16. When the tool 10 is in its locked position (as shown), the at least one dog 76 in the second end 64 of the slip housing 14 is held firmly within the annular recess 92 in the lower housing 16 by the area of increased diameter 129 on the first extension 124 of the piston 22, which thereby holds the slip housing 14 and the lower housing 16 together in tension. When the tool 10 is being shifted to its released position (not shown), the piston 22 is urged upwardly--under action of the propellant 28, as will be discussed more fully below--so that the shoulder 127 on the piston 22 engages the second end 64 of the slip housing 14, and the at least one dog 76 on the slip housing 14 moves inwardly along the inclined surface 128 and into the area of reduced diameter 130, thereby disconnecting the slip housing 14 from the lower housing 16. As will be more fully discussed below, the piston 22 then forces the slip housing 14 upwardly to separate the loading nut 12 from the slips 18a and 18b, and thereby disengage the emergency release tool 10 from the coiled tubing 11.
With reference to FIG. 1C, the collet 24 is disposed around the second extension 126 of the piston 22 and within the longitudinal bore 82 of the lower housing 16, and includes a body portion 132 having a plurality of fingers 134 depending therefrom. Distal ends 135 of the fingers 134 each include a threaded portion 136 for mating with the threaded portion 94 in the longitudinal bore 82 of the lower housing 16. When the tool 10 is in the locked position (as shown), the threaded portions 136 on the collet fingers 134 are engaged with the threaded portion 94 in the longitudinal bore 82 of the lower housing 16, and the collet body 132 is releaseably secured to the second extension 126 of the piston 22, for example, by at least one shear pin 138. The function and operation of the collet 24 will be explained below.
Referring to FIG. 1D, the charge mandrel 30 is disposed within the longitudinal bore 82 of the lower housing 16, and includes a main body portion 140, a first extension 142, and a lower end 143 (FIG. 1E). The first extension 142 includes a longitudinal bore 146 extending therethrough having a threaded portion 148 for mating with the threaded portion 122 at the second end 112 of the slip case 20. The first extension 142 also includes an outer surface 150 having a threaded portion 152 (FIG. 1C) at a distal end 144 of the first extension 142, and a propellant retaining shoulder 154 (FIG. 1D), the functions of which will be explained below. The main body portion 140 includes a longitudinal bore 156 extending therethrough, an electrical conductor conduit 158, at least one drilling fluid flowpath 159, an outer surface 160 having a loading shoulder 162 for bearing against the annular load bearing shoulder 96 in the longitudinal bore 82 of the lower housing 16, and a threaded portion 164 (FIG. 1E) at the lower end 143 of the charge mandrel 30. An electrical connector 165, such as a single-pin feed-through bulkhead connector, may be disposed in the electrical conductor conduit 158 at the lower end 143 of the charge mandrel 30. As will be more fully explained below, one of the electrical conductors (not shown) in the conductor cable (not shown) running from the earth's surface (not shown) to the tool 10 is connected to the electrical connector 165, and another electrical conductor (not shown) connects the electrical connector 165 to the propellant 28 (FIG. 1D) so that the propellant 28 may be remotely ignited from the earth's surface via the conductor cable.
Referring to FIG. 1C, the propellant retainer ring 26 is an annular ring having a longitudinal bore 166 extending therethrough, an outer surface 168, a first edge 170, and a second edge 172. The longitudinal bore 166 includes a threaded portion 174 for mating with the threaded portion 152 on the first extension 142 of the charge mandrel 30. The outer surface 168 preferably includes at least one recess 176 to facilitate the passage of gases generated upon ignition of the propellant 28, as will be more fully explained below. However, since the retainer ring 26 is not sealed, the propellant gases will still expand past the ring 26 in the absence of any recess 176. The outer surface 168 also includes a locking shoulder 178 adjacent the first edge 170 of the ring 26 for loading the collet 24, as will be more fully explained below. The ring 26 is disposed around the outer surface 150 of the first extension 142 of the charge mandrel 30 and extends past the distal end 144 of the first extension 142. As shown in FIGS. 1C and 1D, when the tool 10 is in the locked position (as shown), the propellant 28 is disposed between the longitudinal bore 82 of the lower housing 16 and the outer surface 150 of the first extension 142 of the charge mandrel 30, and is held in place between the second edge 172 of the ring 26 and the retaining shoulder 154 on the charge mandrel 30.
Referring to FIG. 1E, the extension 32 includes a longitudinal bore 180 extending therethrough, a first end 182, and a second end 184. The longitudinal bore 180 includes a threaded portion 186 for mating with the threaded portion 164 adjacent the lower end 143 of the charge mandrel 30. An upper portion of an uppermost tool in the bottom hole assembly (not shown) may be sealably received within the longitudinal bore 180 at the second end 184 of the extension 32.
As discussed above, a conductor cable (not shown) runs from a control panel (not shown) at the earth's surface (not shown) through the coiled tubing 11, through the tool 10, and down to the various tools in the bottom hole assembly (not shown) to which the tool 10 is connected. Drilling fluid also flows from the earth's surface (not shown) through the coiled tubing 11, through the tool 10, and down through the bottom hole assembly (not shown). The tool 10 may be provided with a sealing assembly--consisting of the anchor 34, the armor nut 36, the conductor cable sealing connector 38, and the flow tube 40--to seal the electrical conductors within the conductor cable (not shown) from the drilling fluid. While the conductor cable has not been shown, it will be understood by those of ordinary skill in the art that one specific embodiment of a conductor cable may include a number of electrical conductors that are encased first by an armor, and then by an outer protective shell. In another specific embodiment, the conductor cable may include fiber optic conductors.
Referring to FIG. 1B, the anchor 34 includes a longitudinal bore 188 extending therethrough, a first end 190, a second end 192, a first outer surface 194 adjacent the first end 190, a second outer surface 195 adjacent the first end 190, and an outer surface 196 adjacent the second end 192. The outer surface 196 at the second end 192 of the anchor 34 includes a threaded portion 198 and an inclined portion 200. The longitudinal bore 188 may include a set of seals 202 for sealing against the outer protective shell of the conductor cable (not shown). As best shown in FIG. 8, which is a cross-sectional view taken along line 8--8 of FIG. 1B, the first outer surface 194 at the first end 190 of the anchor 34 has a diameter approximately equal to the inside diameter of the coiled tubing 11. Drilling fluid flow areas 203 exist between the coiled tubing 11 and the second outer surface 195 at the first end 190 of the anchor 34 to allow drilling fluid to flow past the anchor 34, through the longitudinal bore 108 of the slip case 20, and through the drilling fluid flowpaths 159 (FIG. 1D) in the charge mandrel 30 to the bottom hole assembly (not shown).
With reference to FIG. 1B, the armor nut 36 includes a longitudinal bore 204 extending therethrough, a first end 206, a second end 208, and an outer surface 210. The longitudinal bore 204 includes a threaded portion 212 for mating with the threaded portion 198 on the second end 192 of the anchor 34, and an inclined surface 214 for cooperating with the inclined portion 200 on the second end 192 of the anchor 34 to retain the conductor cable's armor (not shown) in a folded-back position, as will be discussed more fully below. The outer surface 210 includes a threaded portion 216 at the second end 208 of the armor nut 36, the purpose which will be explained below. The longitudinal bore 204 includes an annular shoulder 218 and a keyway 219 at the second end 208 of the armor nut 36 for retaining the conductor cable sealing connector 38, as will be more fully discussed below.
The flow tube 40 includes a longitudinal bore 220 extending therethrough, a first end 222, a second end 224 (FIG. 1D), and an outer surface 225. Referring to FIG. 1B, the longitudinal bore 220 includes a threaded portion 226 for mating with the threaded portion 216 at the second end 208 of the armor nut 36, and an annular shoulder 228 for cooperating with the annular shoulder 218 in the longitudinal bore 204 of the armor nut 36 to retain the conductor cable sealing connector 38. Referring to FIG. 1D, the outer surface 225 of the flow tube 40 may include a set of seals 230 adjacent the second end 224 thereof, which is disposed within the longitudinal bore 156 of the main body portion 140 of the charge mandrel 30.
Referring to FIG. 1B, in a specific embodiment, the conductor cable sealing connector 38 may be a three-part cylindrical plug including a metal carrier plug 232, a composite seal 234, and a metal follower plug 236. In a specific embodiment, the composite seal 234 may include a Teflon™ ring 238 disposed between first and second graphite-impregnated rings 240 and 242, such as those sold under the name Grafoil™. A plurality of longitudinal bores 244 extend through the connector 38 (i.e., through the metal carrier plug 232, the composite seal 234, and the metal follower plug 236). The conductor cable's individual electrical conductors (not shown) pass through the longitudinal bores 244 and into the longitudinal bore 220 of the flow tube 40. The conductor cable's individual conductors (not shown) are sealed by compressing the composite seal 234 between the carrier plug 232 and the follower plug 236, which are forced towards each other by threading the flow tube 40 onto the second end 208 of the armor nut 36. The follower plug 236 includes a key 237 for mating with the keyway 219 in the longitudinal bore 204 at the second end 208 of the armor nut 36. The key 237 and keyway 219 prevent the follower plug 236--and the conductor cable's individual electrical conductors (not shown) that pass through the longitudinal bores 244--from rotating when the flow tube 40 is being threaded onto the armor nut 36. The individual electrical conductors (not shown) extend through the longitudinal bore 220 of the flow tube 40, through the longitudinal bore 156 of the charge mandrel 30, and through the longitudinal bore 180 of the extension 32 to the BHA. As already explained above, one of the individual electrical conductors (not shown) is connected to the electrical connector 165 (FIG. 1E) at the lower end of the charge mandrel 30 for igniting the propellant 28.
The operation of the emergency release tool 10 will now be explained. The tool 10 is connected to the coiled tubing 11 and to the remainder of the BHA at the earth's surface, before being lowered into a wellbore (not shown). As noted above, when attaching the tool 10 to the coiled tubing 11, only deburring of the coiled tubing 11 is necessary for installation. This allows simple and cost effective field assembly to be completed quickly at any time. After the coiled tubing 11 is deburred, the conductor cable is connected to the sealing assembly (i.e., the anchor 34, the armor nut 36, the conductor cable sealing connector 38, and the flow tube 40), to the electrical connector 165, and to the BHA, in the manner discussed above. The coiled tubing 11 is then inserted into the tool 10 to the position as shown in FIG. 1A. When the coiled tubing 11 is first inserted into the tool 10, the loading nut 12 is in an unloaded or loose position (not shown). At this time, the remainder of the tool 10 is positioned as shown in FIGS. 1A-1E. When properly inserted, the coiled tubing 11 is disposed within the longitudinal bore 42 of the loading nut 12, within the inner surfaces 98a and 98b of the slips 18a and 18b, within the longitudinal bore 108 of the slip case 20 at the first end 110 thereof, and around the first outer surface 194 at the first end 190 of the anchor 34 (FIG. 1B). The threads 58 on the loading nut 12 are then threaded into the threads 66 on the slip housing 14. In this manner, the flared portion 50 on the second end 46 of the loading nut 12 is forced downwardly against the corresponding flared ends 100a and 100b of the slips 18a and 18b, thereby causing the gripping teeth 104a and 104b on the slips 18 to securely engage and hold the coiled tubing 11 within the tool 10. To ensure that the slips 18 are loaded onto the coiled tubing 11, the tool 10 is designed so that the shoulder 56 on the loading nut 12 may not come into contact with the first end 62 of the slip housing 14. The second end 86 of the lower housing 16 is then connected to the remainder of the BHA, as by the quick disconnect coupler 246, as shown in FIGS. 2-5, to be discussed below.
If the BHA (not shown) becomes lodged downhole during the drilling operation to the extent that the coiled tubing 11 is not sturdy enough to impart the required force to dislodge the BHA, then the emergency release tool 10 may be remotely activated from the earth's surface (not shown) to release the coiled tubing 11. The release of only the coiled tubing 11 leaves no enlarged or "upset" diameters or areas attached to the coiled tubing 11 to hinder its removal from the well. As discussed above, the coiled tubing 11 is released by sending an electrical signal to ignite the propellant 28, and thereby shift the tool 10 from a locked position (as shown) to a released position as depicted in FIGS. 10A-10E. When the propellant 28 is ignited, tremendous forces are generated by expanding gas pressure. The expanding gas pressure travels through the at least one recess 176 in the propellant retainer ring 26 and forces the piston 22 upwardly, thereby shearing the at least one shear pin 138 and releasing the piston 22 from the collet 24, which is attached by threads 94 and 136 to the lower housing 16. The expanding gas pressure continues to force the piston 22 upwardly. As the shoulder 127 on the piston 22 engages the second end 64 of the slip housing 14, the at least one dog 76 on the slip housing 14 moves inwardly along the inclined surface 128 and into the area of reduced diameter 130, thereby relieving tension between the slip housing 14 and the lower housing 16. At this point, the lower housing 16 may shift downwardly to cause the distal ends 135 of the collet fingers 134 to abut against the locking shoulder 178 on the propellant retainer ring 26. The expanding gas pressure continues to force the piston 22 and the slip housing 14 upwardly to separate the loading nut 12 from the slips 18a and 18b, and thereby disengage the emergency release tool 10 from the coiled tubing 11. As the tool 10 is shifted to its released position, the shoulder 69 on the slip housing 14 engages the shoulder 115 on the slip case 20, and the locking dogs 120a and 120b on the slip case 20 move radially outwardly under the force of springs 122a and 122b to engage the annular recess 68 in the slip housing 14, thereby preventing the loading nut 12 from causing the slips 18 to re-engage the coiled tubing 11. The coiled tubing 11 and conductor cable (not shown) may then be removed from the tool 10, thereby exposing the fishing profile 48 (discussed above) on the loading nut 12. When the coiled tubing 11 and conductor cable are pulled from the tool 10, the sealing assembly (i.e., the anchor 34, the armor nut 36, the conductor cable sealing connector 38, and the flow tube 40) is also pulled from the tool 10.
A conventional tubing string (not shown), that is more robust and capable of withstanding far greater tensile loads than the coiled tubing 11, equipped with a conventional well tool (not shown) may be used to engage the fishing profile 48 to pull the tool 10 and BHA from the well. The upward force of the tubing string is transferred to the BHA via (1) the shoulder 69 on the slip housing 14 which is bearing against the shoulder 115 on the slip case 20, and (2) the locking shoulder 178 on the propellant retainer ring 26 which is bearing against the distal ends 135 of the collet fingers 134; the load is transferred from the collet fingers 134 through the threaded portions 94 and 136 to the lower housing 16 and on to the BHA. The threaded portions 94 and 136 are designed to fail at a preselected load. If that failure load is exceeded, the collet 24 will become disengaged from the lower housing 16, and all parts of the tool 10 will be removed, except for the lower housing 16, which will remain attached to the BHA. At this point, a second attempt at removing the BHA using a conventional tubing string and well tool may made. Under this scenario, the annular recess 92 and/or the annular load bearing shoulder 96, both in the longitudinal bore 82 of the lower housing 16, may function as "fishing" profiles. The lower housing 16 is designed to withstand greater pulling forces than the collet 24 or the related threaded portions 136 and 94.
In the event the tool 10 malfunctions or the coiled tubing 11 becomes stuck, conventional well tools may be used to cut the coiled tubing 11 at a point near the tool 10. To do this, the conductor cable (not shown) must be removed from the interior of the coiled tubing 11. The conductor cable is removed by simply pulling it with sufficient force to shear the armor that has been folded back between the inclined portion 200 of the anchor 34 and the inclined surface 214 of the armor nut 36. After the conductor cable has been removed, a conventional well tool may be lowered into the interior of the coiled tubing 11 to cut the coiled tubing 11 near the tool 10, in any manner known to those of ordinary skill in the art. The portion of the coiled tubing 11 above the cut may then be removed, and another conventional well tool may be lowered into the well to fish the remaining portion of the coiled tubing 11 from the well, in any manner known to those of ordinary skill in the art.
With reference to FIGS. 2-5, the quick disconnect coupler 246 of the present invention will now be described. As shown in FIG. 2, in a broad aspect, the quick disconnect coupler 246 includes a box (or female) connector 248, a pin (or male) connector 250, a two-part load ring (or rigid spacer) 252, and a load ring retainer 254.
As shown in FIGS. 3 and 4, the box/female connector 248 includes a longitudinal bore 256 extending therethrough, a first end 258, and a second end 260. At the first end 258 of the box/female connector 248, the longitudinal bore 256 includes a plurality of ribs 262 that are preferably evenly spaced about the circumference of the longitudinal bore 256, and a plurality of grooves 264 defined between the ribs 262. Each rib 262 includes a recess 266 disposed between a first leg 268 and second leg 270. The first leg 268 includes a distal end 272 and the second leg 270 includes a distal end 274. The distal end 274 of the second leg 270 is located closer to the first end 258 of the box/female connector 248 than is the distal end 272 of the first leg 268.
As shown in FIG. 5, the pin/male connector 250 includes a shoulder 276 adjacent a main body portion 278 and a pin member 280. The pin member 280 includes a plurality of lugs 282 for mating with the recesses 266 in the ribs 262 on the box/female connector 248 (FIG. 3), as will be more fully explained below. The pin member 280 further includes at least one seal groove 284 for receiving a sealing ring 286, as shown in FIG. 2.
The purpose of the quick disconnect coupler 246 is to enable various downhole tools, such as the emergency release tool 10 or the individual component tools that make up a BRA (not shown), to be quickly and efficiently connected and disconnected. The quick disconnect coupler 246 achieves this purpose by connecting, as by threads, the box/female connector 248 to one end of a first tool (not shown) and the pin/male connector 250 to a mating end of a second tool (not shown). Once the tools that are desired to be connected are equipped with the connectors 248 and 250, the tools may be quickly connected by: (1) sliding the lugs 282 on the pin/male connector 250 into the grooves 264 on the box/female connector 248 until the shoulder 276 on the pin/male connector 250 abuts against the first end 258 of the box/female connector 248, and the lugs 282 extend past the distal ends 274 of the second legs 270 of the ribs 262; (2) rotating the pin/male connector 250 a fraction of a full 360 degree turn until the lugs 282 contact the first legs 268 on the ribs 262 and are positioned adjacent their corresponding recesses 266; (3) sliding the lugs 282 into their corresponding recesses 266; and (4) fastening the load ring 252 around the pin member 280, and between the shoulder 276 on the pin/male connector 250 and the first end 258 of the box/female connector 248. The pin/male connector 250 and the box/female connector 248 may be alternately locked and unlocked by a rotation of either connector. The load ring 252 prevents the lugs 282 from exiting the recesses 266 and also transmits compressive loads through the connection. The lugs 282 and ribs 262 transmit all tensile and torque forces through the connection. The sealing rings 286 maintain a fluidic pressure seal between the box/female connector 248 and the pin/male connector 250. As noted above, this connection allows minimal rotation of parts being assembled, eases and quickens repair or replacement of components, provides a universal profile to simplify custom configurations, and enables a beneficial modularity whereby specific devices may be added, removed, or changed in relative position in the BHA.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | An improved emergency release tool is provided to releasably connect a coiled tubing to one or more downhole tools. The emergency release tool broadly includes a releasable slip for holding a coiled tubing, the releasable slip being secured to a first end of a slip case, the slip case being disposed within a slip housing and a lower housing, the slip housing being movable from a locked position to a released position; a piston slidably disposed about the slip case and being moveable from a locked position to a released position; a first end of the lower housing being releasably connected to a second end of the slip housing when the slip housing is in its locked position; and, a remotely activated means for moving the piston and the slip housing from their locked positions to their released positions to disengage the releasable slip from the coiled tubing and enable the coiled tubing to be removed from the tool. A quick disconnect coupler is also provided, and broadly includes a pin connector having a series of lugs; a box connector for receiving the pin connector and having a series of recesses to engage and hold the lugs inside the box connector; and, a load ring between the box connector and the pin connector for transmitting compressive loads through the connection. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a thermopheumatic actuator especially suited for controlling the temperature in the passenger compartment of an automotive vehicle.
Passenger automobiles and trucks are normally provided with heating and air conditioning systems for maintaining the desired temperature in the vehicle passenger compartment. The temperature is controlled by selectively energizing the heating and air conditioning systems and furthermore by positioning a temperature door which controls the mixture of hot and cold air.
The temperature door is generally positioned by means of a vacuum actuator which is fed with modulated vacuum from the vehicle intake manifold. The actuator typically comprises a diaphragm which is positioned by opposing forces of the modulated vacuum and a diaphragm spring. The vacuum actuator may be provided with a power diaphragm and a pilot diaphragm to increase the accuracy and decrease the effects of variations in the mechanical resistance encountered in moving the temperature door.
The vacuum to the actuator is modulated by means of a thermally controlled valve. A bimetal spring exposed to air from the passenger compartment positions a valve element to bleed air into the vacuum actuator and thereby reduce the vacuum as a function of temperature. Such a thermally controlled valve is generally referred to in the art as a thermostatic vacuum regulator.
A system of this type is an open loop control system since there is no mechanical feedback between the diaphragm and the valve. Thus, the system is inherently inaccurate since such factors such as variations in the vacuum applied to the regulator, ageing of the diaphragm, pressure drops between the regulator and the actuator and the like will cause the temperature to be controlled in an erratic manner. In addition, the system is disadvantageous from an installation standpoint since the regulator and actuator are separated units. They must be mounted in separate locations and connected by a conduit, constituting unnecessary consumption of mounting space, installation time and expense.
SUMMARY OF THE INVENTION
The present invention overcomes the above described drawbacks of the prior art by combining a thermostatic vacuum modulator valve and a vacuum actuator into an integral unit and providing mechanical feedback in the form of a feedback spring between a bimetal spring of the modulator valve and a diaphragm of the vacuum actuator, thereby providing a closed loop control system.
It is an object of the present invention to provide a thermopneumatic actuator which is immune to variations in output load.
It is another object of the present invention to provide a thermopneumatic actuator comprising a closed loop servo system which is more accurate than prior art open loop servo systems.
It is another object of the present invention to provide a thermopneumatic actuator comprising an improved aspirator means for causing air flow through the actuator housing.
It is another object of the present invention to provide a thermopneumatic actuator which can be manufactured and installed with increased economy in cost and space.
It is another object of the present invention to provide a generally improved thermopneumatic actuator.
Other objects, together with the foregoing, are attained in the embodiments described in the following description and illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a prior art thermopneumatic actuator;
FIGS. 2, 3 and 4 are graphs illustrating the operation of the prior art actuator shown in FIG. 1;
FIG. 5 is a schematic view of a thermopneumatic actuator system embodying the present invention;
FIG. 6 is a longitudinal sectional view of the present actuator;
FIG. 7 is a rear elevation of the present actuator;
FIG. 8 is a fragmentary enlarged sectional view of the present actuator;
FIG. 9 is an enlarged perspective view of a bimetal spring of the present actuator;
FIG. 10 is a schematic view of a first modification of the present actuator;
FIG. 11 is a longitudinal sectional view of the first modification;
FIG. 12 is a section taken on a line 12--12 of FIG. 11;
FIG. 13 is similar to FIG. 12 but shows an alternative arrangement;
FIG. 14 is a longitudinal sectional view of a second modification of the present actuator;
FIG. 15 is a rear elevation of the second modification;
FIGS. 16 and 17 are enlarged sectional views of various portions of the second modification;
FIG. 18 is a simplified schematic view of a third modification of the present actuator; and
FIG. 19 is a section taken on a line 19--19 of FIG. 18.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the thermopneumatic actuator of the invention is susceptible of numerous physical embodiments, depending upon the environment and requirements of use, substantial numbers of the herein shown and described embodiments have been made, tested and used, and all have performed in an eminently satisfactory manner.
Referring now to FIG. 1 of the drawing, a prior art thermopneumatic actuator system is generally designated by the reference numeral 11 and comprises a thermostatic regulator 12. Temperature controlled air is fed into a vehicle passenger compartment (not shown) through a duct 13. Although not shown in FIG. 1, a heater and air conditioner are provided with switch means and a temperature control door to control the air temperature in the duct 13. An inlet hose 14 is connected at one end to the interior of the passenger compartment and at the other end to the interior of the regulator 12.
A tube 16 leads from the duct 13 and discharges pressurized air from the duct 13 into the atmosphere. A hose 17 which leads from the regulator 12 has its other end flared as indicated at 18 and disposed coaxially inside the tube 16. The flared end of the hose 17 in combination with the inner wall of the tube 16 constitutes a venturi which creates a low pressure area at the opening of the hose 17.
Although the interior of the regulator 12 is not shown in detail, it comprises a bimetal spring and a pressure modulator valve which is controlled by the spring. The initial spring tension and thereby the desired air temperature are set by a dial 19 located inside the passenger compartment and connected to the regulator 12 by a cable 21. The spring is located inside a temperature chamber having an inlet and outlet connected to the hoses 14 and 17 respectively. The tube 16 and flared end of the hose 18 constitute an aspirator which sucks air from the passenger compartment through the regulator 12 by the venturi effect.
The valve of the regulator 12 has an inlet connected to the intake manifold of the vehicle (not shown) through a hose 22 of an outlet connected to a vacuum actuator 24 through a hose 23. The regulator 12 serves to modulate the vacuum from the intake manifold in accordance with FIG. 2. In brief, the regulator 12 decreases the vacuum as the air temperature inside the passenger compartment increases.
The actuator 24 comprises a housing 26 which is partitioned by a flexible diaphragm 27. A diaphragm spring 28 urges the diaphragm 27 rightwardly through a spring retainer cup 29 which is fixed to the center of the diaphragm 27. Another cup 31 is fixed to the diaphragm 27 and carries an output rod 32 which is connected to the temperature control door and switches to control the temperature in accordance with the axial position of the rod 32. The temperature is increased as the rod 32 is moved leftwardly. The diaphragm 27 constitutes a wall of a pressure chamber 33 inside the housing 26, with the pressure in the pressure chamber 33 being negative gage pressure or vacuum from the vehicle intake manifold as modulated by the regulator 12. The diaphragm 27 and rod 32 are positioned by the opposing forces of vacuum in the pressure chamber 33 and the spring 28.
In operation, the bimetal spring in the regulator 12 thermally deforms in accordance with sensed temperature and controls the valve to modulate the vacuum supplied into the pressure chamber 33. The diaphragm 27 and thereby the rod 32 assume and equilibrium position at which the vacuum urging the diaphragm 27 leftwardly equals the rightward force of the diaphragm spring 28. If the sensed temperature rises above the desired value, the regulator 12 decreases the vacuum allowing the spring 28 to move the diaphragm 27 and rod 32 rightwardly to decrease the temperature. The opposite effect occurs if the temperature decreases below the desired value.
The temperature regulation of the system 11 is very poor for, among other reasons, a hysterisis effect which is illustrated in FIGS. 3 and 4. For each value of sensed temperature the regulator 12 produces a corresponding value of vacuum. Thus, the system 11 is open loop in the respect that there is no mechanical feedback from the actuator 24 to the regulator 12. The actuator 24 exhibits mechanical hysterisis due to mechanical friction in moving the temperature control door as illustrated in FIG. 3. FIG. 4 is obtained by combing FIGS. 2 and 3. In other words, due to the coefficient of static friction between the temperature control door and its supporting members, a certain change in temperature and thereby vacuum is required to produce any movement whatsoever of the door. This results in very poor temperature regulation. Although the piloted vacuum actuator described hereinabove reduces the hysterisis problem, the addition of a piloted vacuum actuator to the system 11 would still not produce accurate temperature control since there is no mechanical feedback from the actuator to the regulator, and the system would still be susceptible to erroneous operation caused by variations in intake manifold vacuum, deterioration of the diaphragm, pressure drops in the hose 23 and other factors. In addition, the system would still be difficult and expensive to mount since the regulator and actuator are separate and must be connected by the hose 23.
These problems are completely overcome by a thermopneumatic temperature control system 41 illustrated in FIG. 5 which comprises a thermopneumatic actuator 42 embodying the present invention. The actuator 42 is illustrated in detail in FIGS. 5 to 9.
The system 41 comprises an air conditioning duct 43 through which air is blown into the passenger compartment of an automotive vehicle by a fan 44 in the rightward direction as viewed in FIG. 5. An air conditioner evaporator 46 is disposed inside the duct 43 to cool air passing therethrough. A heater 47 is also disposed in the duct 43 downstream of the evaporator 46. Hot water from the vehicle cooling system is applied to the inlet of a valve 49 through a hose 48. The outlet of the valve 49 is connected to the inlet of the heater 47 through a hose 51. The outlet of the heater 47 is returned to the vehicle cooling system through a hose 52. When the valve 49 is opened, hot water is circulated through the heater 47 to heat air passing through the duct 43 to the passenger compartment.
The amount of air passing through the heater 47 is controlled by a temperature control door 53 which is pivotally supported by a shaft 54. The actuator 42 is connected to the door 53 and valve 49 through a link 56 in such a manner that the door 53 is pivoted clockwise thereby unblocking the heater 47 to a greater extent as the link 56 is retracted toward the actuator 42 or pulled upwardly. The link 56 opens the valve 49 to turn on the heater 47 except when the door 53 is in a closed position illustrated in phantom line. The more the door 53 is moved upwardly, the greater the volume of air which passes through the heater 47 and the higher the temperature of the air supplied into the passenger compartment through the duct 43. The intake manifold of the vehicle is symbolically designated as 57 and is connected to the actuator 42 through a hose 58. The passenger compartment of the vehicle is also symbolically shown and designated as 59, the compartment 59 being connected to the actuator 42 through a hose 61. An indicator 62 for setting the desired temperature in the passenger compartment 59 is disposed inside the compartment 59 for ease of adjustment by the vehicle operator and is connected to the actuator 42 through a cable 63. Air from the compartment 59 is caused to flow through the hose 61, actuator 42 and a hose 64 by means of an aspirator 66 provided to the duct 43. The aspirator 66 comprises a venturi tube 67 leading from the duct 43 through which pressurized air is blown from the duct 43. A tube 68 provided at the end of the hose 64 is coaxially disposed inside the venturi tube 67 in such a manner that air is sucked out of the tube 68 by the low pressure created in the venturi tube 67 due to the flow of air therethrough.
In operation, the desired temperature is set into the actuator 42 by the indicator 62 and the actuator 42 moves the link 56 to position the door 53. If the sensed temperature is above the desired value the actuator 42 will move the door 53 downwardly to reduce the temperature of the air being fed into the passenger compartment 59 to reduce the temperature. The opposite effect occurs if the sensed temperature is too low.
As best seen in FIG. 6, the actuator 42 comprises a diaphragm housing 71 and a valve housing 72 which is fixed to the left end of the diaphragm housing 71 by screws 73 (see FIG. 7). The housing 71 defines therein a pressure chamber 74. Similarly, the housing 72 defines therein a temperature chamber 76.
The right wall of the pressure chamber 74 is constituted by a flexible power diaphragm 77 which is fixed at its periphery to the right edge of the housing 71 by an annular cap 78. A spring retainer cap 79 is fixed to the center of the diaphragm 77 by a pin 81. A diaphragm spring 82 is compressed between the left end of the housing 71 and the cap 79, thereby urging the cap 79 and diaphragm 77 rightwardly. The pin 81 also fixes the link 56 and a cap 83 to the right side of the diaphragm 77 so that the diaphragm 77 and link 56 move in an integral manner.
The temperature chamber 76 has an inlet 85 connected to the hose 61 and an outlet 84 connected to the hose 64 so that air from the passenger compartment 59 is caused to flow through the temperature chamber 76 due to the action of the aspirator 66.
A generally U-shaped bimetal spring 86 is fixedly supported at its lower or right end by a block 87, which is in turn supported by a bolt 88 which threadingly passes therethrough. The bolt 88 is rotatably supported through the left wall of the housing 72 and extends externally therefrom. A compression spring 91 is disposed between the left wall of the housing 72 and the block 87 to take up lost motion and dampen vibration. A rod 89 extends from the left wall of the housing 72 and slidingly passes through the block 87 thereby aiding in the support of the block 87 and preventing rotation thereof.
An arm 92 is fixed to the bolt 88 by means of a setscrew 93. The cable 63 is connected to the end of the arm 92. Tension or slackening of the cable 63 caused by adjustment of the indicator 62 causes the arm 92 and bolt 88 to rotate and the block 87 to move left or right as viewed in FIG. 6 carrying the spring 86 therewith.
A vacuum modulator valve which is generally designated as 94 is provided to the housing 72 and comprises an outlet 96 which communicates with the pressure chamber 74 through a tube 97. A flow restriction 98 is provided in the tube 97. The outlet 96 leads from a valve chamber 99 defined within the housing 72.
A valve element 101 is supported by flexible diaphragms 102 and 103 which hermetically seal the temperature chamber 76 from the valve chamber 99 and pressure chamber 74. While the diaphragms 102 and 103 are equal in area, the diaphragm 102 may be made slightly larger than the diaphragm 103. The diaphragms 102 and 103 allow the valve element 101 to move axially. The right end of the valve element 101 is connected to the pin 81 through a valve or feedback spring 104. The upper or left end portion of the bimetal spring 86 resiliently engages with a shoulder 106 of the valve element 101 and urges the same leftwardly.
The left end of the valve element 101 is formed with an inlet valve seat 107 which communicates with the interior of the temperature chamber 76 through a passageway 108. Another inlet valve seat 109 communicates with the hose 58. A double headed valve element 111 is supported by the valve element 101. More specifically, the valve element 111 has a left ball (not designated) which closes the valve seat 109 when moved leftwardly into engagement therewith. The valve element 111 further has a right ball which is disposed to the right of the valve seat 107 inside the passageway 108 and blocks the same when the valve element 111 is moved rightwardly. The detailed construction of the valve 94 is shown in enlarged form in FIG. 8, and the detailed construction of the spring 86 and block 87 is most visible in FIG. 9.
In operation, the vehicle driver rotates the indicator 62 to set the desired temperature. This causes rotation of the bolt 88 and adjustment of the preload of the spring 86 against the shoulder 106 of the valve element 101. The spring 86 is compressed inwardly, and exerts a leftward force on the valve element 101. The valve spring 104 exerts a rightward force on the valve element 101. Then, although leftward and rightward forces extert on the diaphragms 102 and 103 respectively, these forces are counterbalanced each other because the diaphragm 102 are equal in area to the diaphragm 103, as mentioned above. Accordingly, the valve element 101 is not affected by these forces, but is affected by both the leftward force of the spring 86 and the rightward force of the spring 104 so as to be positioned. An increase in temperature in the temperature chamber 76, which corresponds to the passenger compartment temperature, causes the spring 86 to thermally deform leftwardly and exert a greater force on the valve element 101 against the force of the spring 104. The valve element 101 is positioned when the forces of the springs 86 and 104 thereon are equal. When the sensed temperature corresponds to the desired temperature, the valve element 101 attains an equilibrium position shown in FIG. 6 whereby the left and right balls of the valve element 111 block the valve seats 109 and 107 respectively. This seals the valve chamber 99 and thereby blocks communication between the pressure chamber 74, the temperature chamber 76 which is at atmospheric pressure and the hose 58 which conducts vacuum to the valve seat 109 from the intake manifold 57. Under equlibrium conditions, the vacuum in the pressure chamber 74 urging the diaphragm 77 leftwardly equals the force of the spring 82 which urges the diaphragm 77 rightwardly.
When the temperature in the passenger compartment 59 exceeds the desired temperature the spring 86 thermally deforms or expands leftwardly, thereby moving the valve element 101 leftwardly. The left ball of the valve element 111 abuts against the valve seat 109 blocking the same. The valve element 101 overtravels the valve element 111 with the result that the right ball of the valve element 111 unblocks the valve seat 107 thereby establishing communication between the temperature chamber 76 and the valve chamber 99 through the passageway 108.
This has the further effect of connecting the temperature chamber 76 to the pressure chamber 74 through the valve chamber 99 and tube 97, causing air at atmospheric pressure to bleed into the pressure chamber 74 reducing the level of vacuum. As a result, the spring 82 overcomes the force exerted on the diaphragm 77 by the vacuum in the pressure chamber 74 and moves the diaphragm 77 rightwardly. The link 56 moves with the diaphragm 77, moving the temperature control door 53 toward the closed position to reduce the temperature of air being forced through the duct 43 into the passenger compartment 59.
Rightward movement of the diaphragm 77 extends the valve spring 104 thereby increasing the rightward force thereof on the valve element 101 in opposition to the leftward force of the bimetal spring 86. The diaphragm spring 82 is designed to be much stiffer than the valve spring 104 so that the spring 104 has essentially no effect on the spring 82. The valve element 101 is moved rightwardly until the force of the spring 104 equals the force of the spring 86. At this point, which is the equilibrium position, the right ball of the valve element 111 closes the valve seat 107 and seals the pressure chamber 74.
The opposite effect occurs when the temperature drops below the desired value. The leftward force of the spring 86 on the valve element 101 is decreased and the spring 104 pulls the valve element 101 rightwardly. Due to the arrangement of the right ball of the valve element 111 and the valve seat 107, the valve element 111 is pulled rightwardly by the valve element 101 and the left ball of the valve element 111 unblocks the valve seat 109. This connects the pressure chamber 74 to the intake manifold 57 through the tube 97, valve chamber 99, valve seat 109 and hose 58. Thus, air is sucked out of the pressure chamber 74 increasing the level of vacuum.
As a result, the diaphragm 77 and link 56 are pulled leftwardly to further open the temperature control door 53. The spring 104 is slackened by the rightward movement of the diaphragm 77 and the force thereof on the valve element 101 decreases. The valve element 101 is moved leftwardly by the spring 86 until the spring forces are equal and the left ball of the valve element 111 seats against the valve seat 109 to seal the pressure chamber 74.
In summary, it will be seen that the link 56 is positioned by the diaphragm 77 as a function of the level of vacuum or negative gage pressure in the pressure chamber 74. The level of vacuum is determined by the valve 94 which is operated by the bimetal spring 86. Mechanical feedback from the diaphragm 77 to the valve 94 is provided by the feedback or valve spring 104 which provides closed loop control. Thus, the above mentioned drawbacks of the prior art are overcome and the present system 41 operates with extremely improved precision. Various obvious modifications to the actuator 42 such as replacing the double headed ball valve element 111 with a sleeve or functionally equivalent valve arrangement and operating the diaphragm assembly with positive gage pressure rather than vacuum such as from a Diesel engine supercharger will become immediately apparent to one skilled in the art.
While the diaphragms 102 and 103 are equal in area, the diaphragm 102 may be made slightly larger than the diaphragm 103.
FIGS. 10 to 12 illustrate a modification of the present actuator 42 in which an aspirator 66a is provided integrally with the actuator body. This facilitates installation even further since only a simple hose connection is necessary at the duct 43. Like elements are designated by the same reference numerals used in the embodiment of FIGS. 5 to 9 and elements which are essentially similar in function but modified in configuration are designated by the same reference numerals suffixed with the character "a". Further shown in FIG. 10 is a steering wheel 112 and steering column 113 which are located in the passenger compartment 59.
An actuator 42a comprises a valve housing 72a which is connected to the passenger compartment 59 through the hose 58. A link 56a is provided in shortened form and a bellcrank lever 50 and connecting link 55 are provided between the link 56a and door 53. The evaporator 46, heater 47 and door 53 are constructed and function in the same manner as above although their relative positions are reversed. Retraction of the link 56a into the housing 71a causes the temperature control door 53 to be opened and the air temperature to increase as above.
In the actuator 42a a venturi tube 67a and a tube 68a are provided as integral components of the housing 72a. The venturi tube 67a is connected to the duct 43 by a hose 45. The tube 68a leads directly from a temperature chamber 76a of the housing 72a. In operation, air blown through the venturi tube 67a from the duct 43 through the hose 45 creates a low pressure area at the restriction of the venturi tube 67a which sucks air from the temperature chamber 76a through the tube 68a. Air from the passenger compartment 59 fills the partial vacuum created in the temperature chamber 76a through the hose 58 to cause air circulation through the temperature chamber 76a. A bimetal spring 86a is reversed relative to the spring 86 and deforms inwardly in response to an increase in temperature to urge the valve element 101 leftwardly as above.
FIG. 13 illustrates another modification of the actuator 42 in which corresponding elements are designated by the same reference numerals suffixed by the character "b". The embodiment of FIG. 13 is similar to that of FIGS. 10 to 12 except that in an aspirator 66b the relationship of the venturi tube 67a and tube 68a is reversed in FIG. 13. Provided integrally as part of a housing 72b, a venturi tube 67b leads from a temperature chamber 76b to the atmosphere and a tube 68b leading from the duct 43 is coaxially disposed inside the venturi tube 67b.
FIGS. 14 to 17 illustrate another modification of the actuator 42, in which corresponding elements are designated by the same reference numerals suffixed by the character "c". As a main point of difference the U-shaped bimetal spring 86 is replaced by a straight bimetal spring 86c, which thermally deforms leftwardly in response to an increase in temperature. Thus, the basic operation of an actuator 42c is essentially similar to that of the actuator 42. As another main point of difference, it will be noted that in the actuator 42 the inlet 85 and outlet 84 of the temperature chamber 76 are not axially aligned. This causes the air in the temperature chamber 76 to flow in a turbulent manner and minimize temperature gradients. Thus, the air acts on the spring 86 in a uniform manner.
In some cases where more rapid temperature response is required, it is desirable to provide as shown in FIG. 15 an inlet 85c and outlet 84c in axial alignment and furthermore to align the axes of the inlet 85c and outlet 84c with the center of the spring 86c. This causes essentially laminar flow through the temperature chamber 76c and concentration of the air stream on the central portion of the spring 86c. This causes the spring 86c to deform to a greater extent than if the air acted on the spring 86c in a uniform manner and greater response to variations in air temperature.
Several minor modifications are also illustrated in FIGS. 14 to 17. A limit plate 114 provided to the bolt 88 and a stop 116 provided to the housing 72c with which the limit plate 114 is engageable prevent excessive movement of the bolt 88 and spring 86c. As best seen in FIG. 16, the feedback spring 104 is not connected to the pin 81 and thereby to the center of the diaphragm 77 but to a spring retainer cap 79c by means of a stud 115. The stud 115 is offset from the central axis of the diaphragm 77 and rotatably fits in a hole (not designated) formed through the cap 79c. This allows the spring 104 to rotate as it extends and contracts, thereby eliminating variation of the spring constant as a function of the length of the spring 104.
As illustrated in FIG. 17 the upper end of the spring 86c is connected to the valve element 101 by means of a resilient sleeve 117 and a nut 118 screwed onto the right end of the valve element 101. The valve element 101 passes through a hole (not designated) formed through the upper end of the spring 86c and the nut 118 is tightened so that the spring 86c is firmly held. The resilience of the sleeve 117 serves to dampen vibration of the spring 86c and valve element 101.
FIGS. 18 and 19 illustrate another modification of the actuator 42 in which corresponding elements are designated by the same reference numerals suffixed by the character "d". An actuator 42d is essentially similar to the actuator 42 except that an inlet 85d and an outlet 84d of a temperature chamber 76d are axially aligned with each other and with the central or U-shaped portion of the spring 86.
In summary, it will be seen that the present invention provides a thermopneumatic actuator of greatly improved accuracy compared to the prior art. The present actuator is configured as an integral, compact unit which can be installed with substantially reduced space requirements and cost. Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof. | A thermopneumatic actuator of the invention is used to control an automobile heater and/or air conditioner to maintain a desired temperature in the automobile passenger compartment through a mechanical output member of the actuator. The output member is connected to and moved by a diaphragm which is positioned by vacuum introduced from the automobile intake manifold and works against a diaphragm spring. A valve is controlled by a bimetal spring exposed to air from the passenger compartment to modulate the vacuum applied to the diaphragm. A feedback spring connected between the diaphragm and the valve works against the bimetal spring. An aspirator comprising a venturi tube causes air flow from the passenger compartment around the bimetal spring. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application is a U.S. National Stage Application of International Application of PCT/EP2008/057578 filed Jun. 16, 2008, which claims the benefit of German Patent Application No. 10 2007 027 434.5 filed Jun. 14, 2007, the disclosures of which are herein incorporated by reference in their entirety.
FIELD OF THE DISCLOSURE
[0002] The invention relates to a method for producing adjustment structures fort the structured layer deposition on a wafer of the micro system technology. For this purpose, a vapour penetration mask is used through which layers or layer portions may be deposited in a raised way. Other fabrication methods are also included as well as a set of components (kit of parts) which are adapted for cooperation.
BACKGROUND OF THE DISCLOSURE
[0003] It is frequently necessary in wafer processes of the micro system technology that, during progression or at the end of the fabrication of complex micro electromechanical structures, the semiconductor discs (wafer) or the chip structures, respectively, are provided in part (structured or selective) with layers. Therein, the classical multi layer technology which is based on the deposition of the layer over the whole area and its subsequent, photochemical structuring, cannot be used since either certain partial areas of the wafer/chip are not at all permitted to be coated (for example, such layers can render micro mechanical structures inoperative) and/or a photo chemical structuring is not possible (surface profile, not etchable layers) or the effort is to big.
[0004] Vapour penetration masks are known for a long time, which comprise openings for the material to be deposited. Such masks, for example out of metal, are problematic since, with respect to highly profiled surfaces, misalignments are encountered and the (selective) structures to be deposited, are not exactly delimited thereby. Disadvantages related to quality, yield and packing density come up in this way. The poor adjustability of such hard masks with micro structures has the same disadvantageous effect.
[0005] It is an object of the invention to improve the precision of the deposition of structured layers on processed micro system technology wafers.
SUMMARY OF THE DISCLOSURE
[0006] The object is achieved by means of a method for producing adjustments structures for a selective deposition of material on a wafer of the micro system technology using a vapour penetration mask.
[0007] In the method, two or more protruded or depressed wafer adjustment structures are produced on the micro system technology wafer using a defined structuring technology (claim 1 ). Two or more protruded or depressed mask adjustment structures are also produced on a mask disc which comprises the same diameter as the micro system technology wafer. The defined structuring technology is used. Vapour penetration is openings are formed in the mask disc in order to produce the vapour penetration mask. The vapour penetration openings are adapted to leave defined areas of the micro system technology wafer open (or accessible) when the mask—for example in a self adjusting way—is put onto the wafer. The adjustment is effected through—complementary—adjustment elements on the wafer or the mask respectively.
[0008] The inventive method can, therefore, produce a suitable vapour penetration mask which enables a structured layer deposition on the component disc (in short “wafer”) with self adjusting properties upon a mechanical coupling of the adjustment structures and the mask adjustment structures such that the deposition can be effected through the wafer penetration openings which leaves open the areas of the component disc to be coated and which covers the areas which are not to be coated whereby a precise position adjustment of the wafer penetration openings is defined by means of the adjustment structures of the wafer and the mask adjustment structures.
[0009] The preciseness of the position adjustment is achieved in that the production of the adjustment structures on the component disc and the mask adjustment structures on the vapour penetration mask is made by means of the same structuring method such that, because of the equal diameter of those substrates, relatively uniform processing conditions are present which, therefore, contribute to a precise shaping and positioning of the respective adjustment structures.
[0010] Because of the equal diameters, a suitable handling of the system out of wafer and vapour penetration mask can be achieved during the processing procedure.
[0011] Also a method for the selective material deposition (claim 21 ) is proposed on a micro system technology wafer using a vapour penetration mask and with adjustment structures between the wafer of the micro system technology and the mask. It comprises the formation of at least two adjustment structures on the micro system technology wafer using a defined structuring technology. Furthermore, at least two substantially complementary mask adjustments structures are formed on a mask disc which comprises the same diameter as the wafer of the micro system technology whereby the formation of the adjustments structures is affected using the same structuring technology. Vapour penetration openings are formed in the mask disc for forming the vapour penetration mask. Upon self adjusting positioning of the vapour penetration mask on the wafer of the micro system technology, the vapour penetration openings leave defined areas of the wafer open for a selective material deposition on the micro system technology wafer through the vapour penetration openings of the mask. This is also affected then.
[0012] The kit of parts (set out of components, claim 24 ) also proposed, consists out of a micro system technology wafer and a vapour penetration mask which are adapted to each other and provided for (highly) accurate, selective material deposition by means of adjustment structures on the vapour penetration mask and the micro system technology wafer. At least two protruding or depressed adjustment structures are provided on the micro system technology wafer generated using a predefined structuring technology. At least two essentially complementary, protruding or depressed mask adjustment structures are arranged on a mask disk which has the same diameter as the micro system technology wafer. The fabrication is affected using the predefined structuring technology. Vapour penetration openings are provided in the mask disc in order to produce the vapour penetration mask. The vapour penetration openings allow to open defined areas of the micro system technology wafer for the selective material deposition.
[0013] In further, advantageous embodiments, the predefined structuring technology may comprise a time controlled potassium hydroxide etching of silicon which is used as starting material for the component disc and the vapour penetration opening. Because of a special crystallographic orientation, for example a [100] orientation, an anisotropic etching characteristic is affected as is known, such that flank inclination angles of an exactly defined value can be achieved for protrusions and depressions such that a precise sliding movement one with respect to the other of the respective inclined surfaces upon the mechanical adjustment of the device wafer and the vapour penetration mask.
[0014] In further advantageous embodiments, the silicon material is again chosen as base material for the device wafer and also for the vapour penetration mask, wherein the respective adjustment structures are produced using a plasma chemical etching method such that, also because of the nearly identical processing conditions, very similar dimensions for the complementary structures on the device wafer and the vapour penetration mask are resulting. Also thereby, a very accurate adjustment of the vapour penetration mask relative to the device wafer is assured.
[0015] In further advantageous embodiments, a glass disc is selected as starting material for the vapour penetration mask which glass disc can then be structured, because of the similar properties with respect to the surface roughness, planarity and the like, using a plasma mechanical etching which is used in the same way also for the device wafer such that a high degree of precision in producing the complementary adjustment structures is also resulting in this embodiment.
[0016] In further embodiments, a combination disc out of silicon and glass serves as a starting material for the vapour penetration mask.
[0017] By means of the inventive production of the first adjustment structures and the second mask adjustment structures (on the wafer or the mask, respectively), the formation of the special structures for the vapour penetration mask and the micro system technology wafer is achieved such that an accurate and stable position of the vapour penetration mask is achieved by interaction during the process of deposition.
[0018] Because of the high precision in producing the complementary adjustment structures, not only a very precise adjustment of the areas not to be coated, and the areas on the component disc (wafer) to be coated, is resulting, but these can also reliably separated from each other after the deposition process without undesired mechanical action on the device wafer and the vapour penetration mask being affected. The vapour penetration mask can, thereby, be used for many component discs.
[0019] Further advantageous embodiments are presented in the further dependent patent claims and are clearly apparent from the following description.
[0020] In a modification, a method for self adjusting adjustment structures for a structured layer deposition on a wafer of the micro system technology using a deposition mask or a vapour penetration mask, respectively, is provided whereby the deposition is affected through openings in a vapour penetration mask placed on the wafer and adapted for multiple usage which mask covers the areas of the wafer not to be coated, and the accurate positional adjustment is affected by means of the adjustment structures. The method is characterized thereby that the adjustment structures are produced on the deposition mask as structures protruding from the surface and on the micro system technology wafer as structures depressed with respect to the surface accurately fitting to each other such that the structures engage with each other during the deposition and are adapted to be separated again after the deposition.
[0021] In a further modification, a method for self adjusting adjustment structures for a structured layer deposition on a micro system technology wafer using a deposition mask or a vapour penetration mask, respectively, is provided whereby the deposition is affected through openings in a vapour penetration mask placed on the wafer and being adapted for multiple use which mask covers the areas of the wafer not to be coated, and an accurate positional adjustment is affected through the adjustment structures. The method is characterized in that the adjustment structures are produced on the deposition mask as structures depressed in the surface and on the wafer of micro system technology as structures protruded with respect to the surface (exactly) fitting to each other such that the structures engage within each other during the deposition and are adapted to be separated after the deposition.
[0022] The height of the structures is provided such that no burden or hindrance is affected during adjustment. The kit of parts (claim 28 ) preferably has flank inclination ankles which comprise an inclination between 50° and 70°. Juxtaposed inclined flanks of the mask and the wafer are adjusted with respect to the inclination to each other in the adjustment elements. In case of a KOH etching of the flanks, an inclination of 54, 74° is resulting.
[0023] The invention is now further explained and supplemented with reference to embodiments using the drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0024] In the Figures:
[0025] FIG. 1 a shows schematically a vertical section of a vapour penetration mask 8 and a component disc as wafer 7 having corresponding adjustment structures 5 , 6 or 5 ′, 6 ′ prior to using them in order to define a relative position of the vapour penetration mask and the component disc by means of a contact of the adjustment structures,
[0026] FIG. 1 b , 1 c show a top view or a section view, respectively, of an inventive adjustment structure which is produced by a KOH etching of a (100) silicon disc, wherein the adjustment structure is provided on the micro system technology disc in the shape of a pyramidal (pyramid shaped) depression without tip,
[0027] FIG. 1 d , 1 e show a top view or a section view, respectively, of a mask adjustment structure according to an example of the invention whereby also a (100) silicon disc is used as a base material for the vapour penetration opening,
[0028] FIG. 2 shows schematically a section view of a detail of the combined adjustment components according to FIGS. 1 b to 1 e,
[0029] FIG. 3 a , 3 b , 3 c show corresponding section views of a further area of wafer adjustment structures and mask adjustment structures which are produced by a plasma mechanical etching, wherein FIG. 3 a is a section view of an adjustment structure shape of a depression, FIG. 3 b is a section view of the mask adjustment structure in the shape of a protrusion and FIG. 3 c shows the adjustment components in an assembled arrangement (position).
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] FIG. 1 a shows a section view of a micro system technology wafer 7 which comprises device elements 10 a, 10 b, 10 c, for example as sensible structures 10 a, 10 b, 10 c like MEMS or the like. Furthermore, two or more adjustment structures 5 , 5 ′, for example as depressions in a substrate disc 7 a, are provided. A vapour penetration mask 8 which is provided with vapour penetration openings 9 , 9 ′, leaves certain areas of the wafer 7 free on which a material is to be selectively deposited without exposing one or several sensible areas 10 , for example the element 10 a, to the deposition atmosphere.
[0031] In the embodiments shown, the vapour penetration mask 8 is also produced from a silicon disc which comprises complementary mask adjustment structures 6 corresponding to the adjustment structures 5 and which, thereby, are formed as protrusions. On the other side next to the sensitive area 10 are adjustment structures 5 ′, 6 ′.
[0032] It has to be noted that in the described embodiments, also the adjustment structures 5 of the wafer 7 can be provided as protrusions and the mask adjustment structures 6 in the vapour penetration mask can be provided as depressions.
[0033] In an embodiment, the discs 8 a and 7 a are formed out of silicon having a (100) surface orientation. The wafer 7 of the micro system technology as well as the vapour penetration mask 8 are produced on the basis of a (100) Si disc whereby a high accuracy during production of the adjustment structures by etching steps may be achieved, the etching rate of which depends on the crystallographic orientation.
[0034] In general, methods of the micro system technology are used for achieving a high accuracy of the position of the vapour penetration mask and the structure layout (the arrangement or placing of the vapour penetration openings 9 , 9 ′ or the vapour penetration openings in the micrometer range, respectively). Unstructured wafers out of silicon or glass are used as starting raw material pieces for the vapour penetration mask since those may be processed by the above mentioned methods and provide the best possible conditions with respect to thickness, thickness deviation, planarity and surface quality. Furthermore, they may be adapted to the process applications in their size.
[0035] The openings 9 , 9 ′ are, in an implementation, provided individually and not interconnected or are to be seen, in another implementation, to be continuous as a continuous opening, for example a circular ring or square. There are at least several openings in a mask 8 and several sensible areas 10 on the wafer such that the plural of “openings” is also valid for further openings which are not separately shown.
[0036] Essentially the same diameter as with the system wafer 7 which is to be provided with a deposition is used. In principle, all methods are suitable with which the vapour penetration through-openings 9 and the mechanical adjustment structures 5 and the mask adjustment structures 7 may be produced very accurately. Therein, it is provided in advantageous embodiments that the corresponding, mechanical adjustment structures 5 , 6 or 5 ′, 6 ′ of the system and the deposition mask wafer 7 a, 8 a are produced with the same technology in order to achieve an accurate alignment. The vapour penetration openings 9 may however be also produced with another technology if required. At least two of the adjustment structures 5 , 6 are provided on each of the wafer surfaces 7 a, 8 a in order to enable an accurate adjustment in the X- and Y-direction as well as in the angular direction. More than two structures put up the adjustment ability and accuracy and prevent a possible shifting after alignment.
[0037] FIGS. 1 b and 1 c show a top view or a section view, respectively, of a section of the wafer 7 . As is shown, the adjustment structure 5 is provided in the shape of a pyramid shaped depression in one surface 1 of the disc 7 a, wherein the etched slopes 2 which represent the crystallographic surfaces, are narrowing down and are ending in a deeply etched area 3 which is flat. The pyramid has no tip here but is a stub such.
[0038] FIGS. 1 d and 1 e show a top view or a section view, respectively, of a section of the vapour penetration mask 8 . As is shown, the adjustment structure 6 is provided in the shape of a pyramid shaped protrusion on one surface la of the disc 8 a, wherein etched slopes 2 which represent the crystallographic surfaces, are narrowing down and are ending in an area 3 which is positioned at a higher level and is flat. The pyramid has no tip here but is a stub such.
[0039] In this embodiment, the same accurate alignment of the azimuthal crystallographic orientation of the crystal wafer 7 a, 8 a is used which is characterized each by an engagement edge provided on each wafer and being crystallographic orientated. Upon the processing of the disc 7 a, 8 a, the production of the adjustment structures 5 , 5 ′ and 6 ′, 6 in the identical, horizontal orientation of the disc 7 a, 8 a is used such that the flanks 2 , 2 a are produced as identical, crystallographic surfaces.
[0040] It is a matter of course that etching masks exactly adjusted to each other with respect to geometry and position, are used in the production of the adjustment structures. Hard masks out of an oxide nitride double layer are used for etching whereby the oxide is applied to the silicon and the nitride is provided as upper layer, whereupon this mask is photo chemically structured. The etching is affected in a time controlled manner such that the hole depths (the depression of the area 3 ) and the height of the protrusion (the height of the area 3 a ) may be exactly adjusted to each other.
[0041] The etching rate for many process recipes is known or can be determined efficiently by experiment. Multiple etching is possible whereby the possibility of an improved control of the process output is resulting.
[0042] In an embodiment, crystallographically caused surfaces, for example the flanks 2 , 2 a , are formed by a KOH etching (potassium hydroxide) of single crystal silicon. The inclined surfaces 2 of the holes or depressions 3 , respectively, of the adjustment structures 5 and the inclined surfaces 2 a of the protruding part 3 a of the mask adjustment structures 6 , thereby have the same inclination angle of preferably 54, 74°.
[0043] The inclination angles of the outer corners 4 are protected during etching with compensation structures. Since crystallographic planes which may be etched faster, are located at the corners 4 , 4 * or 4 ′, 4 ″, structures of the angular or tongue type are preferably arranged on these in the etching mask which structures are under-etched but is slow down the etching of the corners in spite of this so much that rectangular or only slightly rounded corners are resulting in the end.
[0044] The stamps or protrusions 3 a, respectively, fit exactly into each other with a high precision in case of an accurate design of the etching masks for the production of the adjustment structures 6 , since the hole 3 and the stamp 3 a are conical and thereby allow a good fitting. A control of the etching processes for the adjustment structures 5 , 6 can suitably be affected by computer supported methods for determining the size of the masks and by simulation of etching.
[0045] FIG. 2 shows the vapour penetration mask 8 and the wafer 7 in an assembled condition. The conical structures produced by means of the exactly controlled etching process and having a high precision, thereby have a good affect of self adjustment since the flanks 2 , 2 a are centring themselves even in case of a lateral offset during the assembly. In order to avoid stress or striking, respectively, upon assembly, the protruding mask adjustment structure 5 is formed in a demonstrative embodiment such that they do not touch the base 3 of the depression 5 . This has the consequence that the masks may be used again very often because of the low mechanical burden.
[0046] The structures shown in FIG. 3 , relate also to silicon wafers.
[0047] In FIG. 3 a , the adjustment structure 5 * is shown in the shape of a depression wherein the flanks 2 * may be adjusted according to the etching conditions.
[0048] FIG. 3 b shows the vapour penetration mask 8 with the complementary mask adjustment structure 6 .
[0049] FIG. 3 c shows the vapour penetration mask and the wafer 7 in an assembled condition wherein also here the protrusion of the adjustment structure 6 does not reach to the bottom of the depression 5 in the shown embodiment in order to improve the assembling procedure as is also described above.
[0050] Upon the production of the adjustment structures shown in FIG. 3 , plasma mechanical silicon etching, such as advanced silicon etching, BOSCH-process, are used. With these etching processes, it is possible to produce vertical and also slightly conical structures in silicon which may serve as adjustment structures 5 and 6 . The latter is achieved by means of a process modification. The conical structures 5 , 6 are better adapted for assembling. The crystallographic orientation does not play a part here. No corner compensation structures are used. A simple etch mask design is concerned.
[0051] Round and multi corner structures are possible. A resist mask is sufficient for etching.
[0052] The adjustment structures can also be produced by means of sandblasting on glass, silicon or combination wafers out of these materials. For this purpose, a hard mask is used. The positioning accuracy is, however, not as high as with the etch embodiments. In other embodiments, also micro drilling and micro machining is used. A hard mask is not necessary for this purpose. The achievable accuracy is high when using a CNC process.
[0053] The four above described processes may be used also for realizing the vapour penetration holes 9 , 9 ′, wherein the KOH etching is again a very advantageous modification since it is economical and the conical holes 9 are very advantageous for the vapour deposition since the vapour is guided into the hole 9 . Suitable vapour penetration holes 9 may, however, also realized by other technologies. In principle, the technologies for the hole structures 9 , 9 ′ and the adjustment structures 5 , 6 , 5 ′, 6 ′ may be combined arbitrarily. With respect to the efficiency of the process, it is advantageous to use the same processes. In case mask processes are used for the structuring of the adjustment structures 6 and the vapour penetration openings 9 , it is advantageous when the masks are applied to both sides of the mask wafer 8 a prior to the first etching. However, it is also conceivable that the etching steps are carried out sequentially from one side thereof.
[0054] It is to be noted that also adjustment structures 5 on the wafer 7 may be provided as protrusions and the mask adjustment structures 6 in the vapour penetration mask may be provided as depressions in the embodiments described.
[0055] In modifications, methods for self-adjusting adjustment structures for a structured layer deposition on a micro system technology wafer using a deposition mask or a vapour penetration mask, respectively, is provided wherein the deposition is affected through openings in a vapour penetration mask to be put onto the wafer and adapted for multiple use which covers the areas of the wafers not to be coated and are reached an accurate position adjustment is effected through the adjustment structures. The method is characterized in that the adjustment structures are produced on the deposition mask as structures protruding from the surface and on the micro system technology wafer as structures lowered with respect to the surface or vice versa, are produced as exactly fitting to each other, such that the structures engage into each other during the deposition and are adapted to be separated again after deposition.
REFERENCE SIGNS (EXCERPT)
[0056] (The same reference signs for the same elements in different Figures)
[0057] 1 surface or bottom, respectively, of the depression
[0058] 1 a surface of the protrusion
[0059] 2 etched flank (crystallographic surface) of the adjustment structure of the wafer
[0060] 2 a etched flank (crystallographic surface) of the vapour penetration mask
[0061] 3 deeply etched area
[0062] 3 a surface of the protruded area
[0063] 4 location of the compensation structures
[0064] 5 , 5 ′ adjustment structure, for example in the shape of an adjustment depression
[0065] 6 , 6 ′ mask adjustment structure, for example in the form of a protrusion
[0066] 7 micro system technology wafer
[0067] 7 a base disc (for example silicon)
[0068] 8 vapour penetration mask
[0069] 8 a base disc (for example silicon)
[0070] 9 , 9 ′ vapour penetration openings
[0071] 10 device element structure area
[0072] 10 a, 10 b, 10 c devices (MEMS) | The invention relates to a method for selective material deposition for sensitive structures in micro systems technology for producing mechanical adjustment structures ( 6, 5 ) for a vapour penetration mask ( 8 ), the adjustment structures on the component disc ( 7 ) and the mask being created using the same structuring method. Complementary adjustment structures can be produced thereon with a very high degree of precision. KOH etching in silicon can be used in order to create equally inclined flanks ( 2, 2 a ) in a depression and a complementary protrusion. | 7 |
BACKGROUND
[0001] A variety of machines in which clothes may be hung and processed in a single unit have been proposed. There are a series of patents that require the use of solvents for dry cleaning garments, for example U.S. Pat. No. 2,845,786, issued to E. L. Chrisman on Aug. 5, 1958; U.S. Pat. No. 3,166,923 issued to Zacks on Jan. 26, 1965; and U.S. Pat. No. 2,741,113, issued to Norkus on Apr. 10, 1056. The use of solvents, especially in the home, can create health and safety issues.
[0002] There are additional patents that claim a machine in which the clothes are “finished” only. These patents are directed toward de-wrinkling and smoothing the clothes, typically by using steam. However, these machines do not clean the clothes, these machines are used after the clothes are already clean. Some examples of these devices are seen in U.S. Pat. No. 3,707,855 issued to Buckley on Jan. 2, 1973; U.S. Pat. No. 4,391,602 issued to Stichnoth et al. on Jul. 5, 1983; U.S. Pat. No. 3,739,496 issued to Buckly et al. on Jun. 19, 1973; U.S. Pat. No. 3,732,628 issued to Bleven et al. on May 15, 1973; and U.S. Pat. No. 4,761,305 issued to Ochiai on Aug. 2, 1988. U.S. Pat. No. 6,189,346 issued to Chen et al. on Feb. 20, 2001 discloses a clothes treating apparatus that uses a “conditioning mist” as an alternative to dry-cleaning clothes. This patent does not provide for washing clothes with water or rinsing the clothes.
[0003] In addition, some patents claim machines that only dry clothes, and do not wash or finish the clothes: for example U.S. Pat. No. 3,257,739 issued to Wentz on Jun. 28, 1966; and U.S. Pat. No. 3,102,796 issued to Erickson on Sep. 3, 1963.
[0004] U.S. Pat. No. 3,114,919 issued to Kenreich on Dec. 24, 1963 discloses a machine that can wash and dry using conventional laundry soap, however, this apparatus can only wash one shirt, or the like, and one pair of pants, or the like, at a time. In addition, this patent discloses an apparatus that has fixed outlets for dispensing wash and rinse water. This patent, like U.S. Pat. No. 3,664,159 issued to Mazza on May 23, 1972, utilizes a shaking of the garments to remove dirt and debris from the garments. However, shaking the garments can cause the garments to fall during the wash cycle, and can impart wrinkles to the garments. In addition, these patents teach that the wash water is applied from the top and bottom of the clothing, and not along the length of the clothing.
[0005] Finally, U.S. Pat. No. 3,672,188 issued to Geschka et al. on Jun. 27, 1972 discloses an apparatus that uses conventional laundry soap water, and hot air to wash and dry clothes. However, in this patent the soap and water are applied to the garments from top and bottom nozzles. Likewise, in U.S. Pat. No. 3,868,835 issued to Todd-Reeve on Mar. 4, 1975, the water and soap are applied from nozzles located near the top and bottom of the apparatus. In neither of these apparatuses is the soap and water applied over the entire length of the garments.
SUMMARY
[0006] In one aspect of the present invention, a garment processing apparatus includes a hanger bar having a plurality of variable width notches, each of the variable width notches being capable of supporting a hanger with a garment thereon, and a cabinet having an interior, the hanging bar being supported in the interior of the cabinet, wherein the cabinet is configured to process one or more of the garments.
[0007] In another aspect of the present invention, a garment processing apparatus includes a hanger bar having a plurality of notches, each of the notches being capable of supporting a hanger with a garment thereon, the hanger bar further comprising means for varying the width of each of the notches, and a cabinet having an interior, the hanging bar being supported in the interior of the cabinet, wherein the cabinet is configured to process one or more of the garments.
[0008] In yet another aspect of the present invention, a method of processing a plurality of garments in an apparatus including a cabinet having an interior and a hanger bar having a plurality of notches in the interior of the cabinet, the method including placing each of a plurality of hangers in a different one of the notches, each of the hangers having a garment thereon, adjusting the width of each of said different one of the notches in accordance with the hanger placed thereon, and processing the garments.
[0009] It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein various embodiments of the invention are shown and described by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
[0011] FIG. 1 is a perspective view of the garment processing apparatus from the front with the door open;
[0012] FIG. 2A is an elevation view of a hanger mechanism for use in the garment processing apparatus;
[0013] FIG. 2B is a plan view of the hanger mechanism;
[0014] FIG. 2C is a detailed cross-sectional plan view of a variable width notch in the hanger mechanism with the notch in the open position;
[0015] FIG. 2D is a detailed cross-sectional elevation view of the variable width notch in the hanger mechanism with the notch in the open position;
[0016] FIG. 2E is a detailed cross-sectional elevation view of the variable width notch in the hanger mechanism with the notch in the closed position;
[0017] FIG. 3A is a plan view of the manifold.
[0018] FIG. 3B is a cross-sectional perspective view of the manifold;
[0019] FIG. 3C shows a partial sectional view of the area indicated in FIG. 3A ;
[0020] FIG. 4 is a functional block diagram illustrating a water system in the garment processing apparatus; and
[0021] FIG. 5 is a functional block diagram illustrating a closed-loop air system in the garment processing apparatus.
DETAILED DESCRIPTION
[0022] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present invention, and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the present invention.
[0023] In one embodiment, a single apparatus may be used to process garments. The term “process” garments means to wash, rinse, dry and/or steam garments. The apparatus may be used in residences or in hotel rooms, hospitals, laundromates, and other commercial applications. In a conventional washing machine it is best to transfer the clothes soon after they are washed to the dryer in order to prevent wrinkling. In addition, it is even better to rapidly remove dried clothes from the dryer shortly after completion of the drying process to further prevent wrinkling. When using the apparatus described herein, there is no need to rapidly move clothes from the washing machine to the dryer, or to rapidly remove clothes from the dryer. The clothes are washed and dried on hangers in the apparatus. Once the cycle is complete, the clothes may remain in the apparatus indefinitely, until ready to be worn, suspended from hangers.
[0024] The apparatus may be used by placing garments on hangers, and hanging the garments on a bar within the apparatus. Plastic hangers, or any other hanger that will support the garments without imparting stains to the wet garments, may be used. A hanger alignment mechanism may also be used to secure the garments in a relatively fixed position during the operating cycle.
[0025] A manifold may be used to supply water, steam and/or air to the clothes. Chemical agents for treating the garments may be injected into the water, steam and/or air stream in the manifold. The manifold may include a series of arms, with one arm on each side of the garment. The arms may contain nozzles directed downward and toward the garments. The manifold, arms, and nozzles may contain a dual internal system of pipes. One set of internal pipes allows wash water and/or rinse water to be directed toward the clothes. The other set of internal pipes allows air and/or steam to be directed toward the clothes.
[0026] During operation, the wash water containing one or more chemical agents such as soap and the like may travel up the first set of internal pipes in the manifold, through the arms, out the nozzles, and onto the clothes. The entire manifold may be configured to traverse up and down the length of the hanging clothes, spraying the clothes with soapy water.
[0027] After the wash cycle is complete, rinse water may travel through the same first set of internal pipes in the manifold, and arms, and out the same nozzle. The manifold may again traverse up and down the length of the hanging clothes, spraying the clothes with rinse water.
[0028] In the drying cycle, air and/or steam may travel through the second set of internal pipes in the manifold, through the arms, and out a separate set of nozzles and toward the clothes. The air may be used to dry the garments and the steam may be used to remove the wrinkles from the garments. Chemical agents may be injected into the steam and/or air stream. The steam, and more particularly, the air may be recirculated through a condenser. The condenser may be used to remove the moisture from the steam and/or air stream.
[0029] The sequence and duration of the wash cycle, rinse cycle, drying cycle and steam cycle may be controlled through a control panel.
[0030] When the washing and drying cycle is complete, the clothes may remain in the apparatus until such time as is convenient to remove the clothes.
[0031] Referring to FIG. 1 , an apparatus 10 may include a cabinet 12 with a front wall 12 a , a rear wall 12 b , two side walls 12 c and 12 d , and a top and bottom wall 12 e and 12 f . The bottom wall 12 f may include a drain 14 . In one embodiment of the apparatus 10 , the walls of cabinet 12 are insulated. The apparatus 10 may be connected to a water supply by hose 16 and an electrical supply by conductors 18 .
[0032] The cabinet 12 , which may be sealed against the escape of water, may be provided with a door 22 through which clothing to be processed can be inserted. In one embodiment of the apparatus, the door 22 may be transparent so that the garments may be viewed during the operating cycle. Alternatively, the door 22 may be opaque and insulated. The door 22 may be attached to the cabinet 12 with one or more conventional hinges 6 . The door 22 may be closed and watertight during operation of the apparatus. The door 22 may, but does not have to, extend the entire length of the front wall 12 a of the cabinet 12 .
[0033] The cabinet 12 may be adjacent to a sub-cabinet 24 . The sub-cabinet 24 may include the mechanism by means of which the operating cycle of the apparatus 10 is automatically carried out. The operating cycle may include any variation or combination of pre-washing, washing, rinsing, steaming and drying. For means of illustration only, and not as a limitation, the control mechanism may allow the consumer to set the apparatus for heavy or light washing; set the water temperature; add chemical agents such as bleach, fabric softeners, or other laundry additives, set one or more rinse cycles; set an initial delay of the start of the wash cycle to allow for the action of spot-removers; set a delay of the start of the wash cycle to accommodate the convenience of the user; set a pre-wash cycle; set varying drying temperatures and times, set a steam cycle after drying to remove wrinkles from the garments, and set the apparatus for steam cycle only to quickly remove wrinkles from garments that do not require washing. The various washing and drying requirements may be set via a control panel 28 . The electricity for running the control panel 28 , and all other parts of the apparatus 10 , may be supplied through the conductor 18 .
[0034] The control panel 28 may be used to effectuate the different washing and drying needs of the user. The control panel 28 may include a timer, a means for setting or programming the various washing, rinse, drying and steam cycles, as well as the temperature for each, a means for dispensing chemical agents such as laundry detergent, bleach, fabric softener, or other laundry additives, and a means for regulating the washing, rinsing, steaming and dying times.
[0035] The clothes-receiving portion of the cabinet 12 may have, at its upper end, a hanging bar 30 . The hanging bar 30 may be suspended horizontally and parallel to the walls 12 a and 12 b . The hanging bar 30 may have one or more hanger notches 32 . Hanger-mounted garments 26 such as clothes, towels, sheets or other items to be laundered may be placed on a conventional, non-rusting, hanger. The hanger may be inserted onto the hanging bar 30 , and held at regularly spaced intervals by the notches 32 in the hanger bar.
[0036] Referring to FIGS. 2A-2E , the hanger bar 30 may be configured with variable width hanger notches 32 that automatically adjust to the hanger width to align the hangers in a parallel manner. The variable width notch 32 may include a sliding notch wall 33 . An actuator 35 , or other similar device, may be used to control the width of the notch 32 by moving the sliding notch wall 33 in and out of the notch 32 . In one embodiment, the actuator 35 may include an elongated horizontal member 37 that extends the length of the hanger bar 30 . The elongated horizontal member 37 may include a number of spaced apart vertical members, one vertical member for each variable width notch. As shown in FIGS. 2C-2E , the vertical member 39 may be coupled to the sliding notch wall 33 of its respective variable width notch 32 with a spring 41 .
[0037] The elongated horizontal member 35 may be moved between an open and closed position by a solenoid (not shown) or other actuating device. FIGS. 2C and 2D show the elongated horizontal member 35 in the open position with the notch 32 in its widest position. In the open position, a hanger 43 may be placed in the notch 32 , or alternatively, removed from the notch 32 . With the hanger 43 in the notch 32 , the actuator 35 may be used to adjust the variable width notch 32 to secure the hanger 43 . This may be achieved by moving the elongated horizontal member 37 into the closed position as shown in FIG. 2E . As the elongated horizontal member 37 is moved into the closed position, the vertical member 39 moves the sliding notch wall 33 inward until it engages the hanger 43 and forces it against the opposite fixed wall 45 of the notch. With the hanger 43 lodged between both the sliding side 33 and the fixed wall 45 of the notch 32 , the spring 41 will begin to compress as the actuator 35 continues to move towards the closed position. This approach allows different diameter hangers to be used in the apparatus. The variable width notch 32 will automatically adjust to the width of the hanger when the elongated horizontal member 37 of the actuator 35 is forced into the closed position.
[0038] As indicated above, the elongated horizontal member 37 of the actuator 35 may be moved between the open and closed position by a solenoid (not shown) or other actuating device. In one embodiment of the hanger bar 30 , the solenoid may be user controlled by a switch (not shown). With this approach, the user can simply place the switch in one position to access the hangers and another position to secure the hangers in place for operation. Alternatively, the solenoid may be controlled automatically. By way of example, a switch (not shown) responsive to the position of the door 22 (see FIG. 1 ) may be used. In this configuration, the notches may be opened into their widest position when the door is opened to release the hangers. When the door is closed, the variable width hanger notch may adjust to the hanger width causing parallel alignment of the hangers during operation.
[0039] Referring to FIGS. 1 and 3 A- 3 C, a manifold 40 may be used to supply water, steam and/or air to the clothes. The manifold 40 may include a plurality of arms 42 . The arms 42 may be in a single plane, parallel to each other, and perpendicular to the hanging bar 30 . The arms 42 may extend between hanger-mounted garments 26 . The first arm in the parallel plane is 42 a , and the last arm in the parallel plane is 42 z.
[0040] The manifold 40 may have two sets of internal pipes. One set is the liquid-carrying pipes 46 , which may be used to transport wash and rinse water. The other set is the air-carrying pipes 47 , which may be used to transport air and steam. The liquid-carrying pipes 46 and air carrying pipes 47 may be a separate set of internal pipes inside manifold 40 . Alternatively, as shown in FIG. 3C , the manifold 40 , liquid-carrying pipes 46 , and air carrying pipes 47 may be manufactured as a single unit with a divider 55 separating the air in the air-carrying pipes 47 from the water in the water-carrying pipes 46 .
[0041] FIG. 4 is a perspective view of a water system, which may be used during the wash and rinse cycles. In the water system, water may enter the sub-cabinet 24 through the water inlet 80 attached to the water supply hose 16 . A water pump 82 may be used to pump the water through a heater 84 to the manifold 40 . A flexible pipe 86 may be used to connect a rigid pipe 85 extending from the heater 84 to the manifold 40 .
[0042] A reservoir 88 may be provided for laundry detergent or other chemical agents that may be injected into the water stream, as requested by the user. A peristaltic pump 90 , or any other suitable pump, may be used to draw the chemical agents from the reservoir 88 and inject them into the water stream through a nozzle 92 penetrating the rigid pipe 85 . The peristaltic pump 90 may be disabled during the rinse cycle.
[0043] In either case, once the water (with or without chemical agents) reaches the manifold 40 , it may exit the arms 42 and spray the hanger-mounted garments 26 . The manifold 40 may move up and down the length of the hanger-mounted garments 26 spraying both sides of garments 26 with the water. The water may run off the garments 26 , down to the bottom wall 12 f , through the drain 14 , and back to the water pump 82 . A waste water valve 94 may be used to recirculate the water, or discharge the water through a water outlet pipe 96 .
[0044] FIG. 5 is a perspective view of an air system, which may be used during the drying and steam cycle. In the air system, air may be drawn from the cabinet 12 through an air intake port 98 by a blower 100 . The blower 100 may be a variable speed or fixed speed blower. A condenser 102 may be inserted in-line between the air intake port 98 and the blower 100 . The condenser 102 may be used to remove water from the air drawn from the cabinet 12 . The condensed water may be discharged through a water ejection tube 104 . The water ejection tube 104 may be connected to the water outlet pipe 96 in the water system.
[0045] The blower 100 may be used to force the air drawn from the cabinet 12 through a heater 106 and into the manifold 40 . A flexible pipe 108 may be used to connect a rigid pipe 110 extending from the heater 106 to the manifold 40 . The rigid pipe 110 may provide a suitable location for injecting various elements into the air stream. By way of example, a steam generator 112 may be used to inject steam into the air stream through a nozzle 114 penetrating the rigid pipe 110 . A reservoir 116 may also be used as a container for chemical agents that may be injected into the air stream. A peristaltic pump 118 , or any other suitable pump, may be used to draw the chemical agents from the reservoir 116 and inject them into the air stream through a nozzle 120 also penetrating the rigid pipe 110 .
[0046] Once the air stream reaches the manifold 40 , it may be directed to the hanger-mounted garments 26 through the arms 42 . The manifold 40 may move up and down the length of the hanger-mounted garments 26 blowing air or steam on both sides of garments 26 .
[0047] Returning to FIGS. 3A-3C , each arm 42 of the manifold 40 may include a plurality of liquid-exits 44 and air-exits 45 . The liquid-exits 44 and the air-exits 45 may be either nozzles or holes. Arm 42 a may include a plurality of exits 44 a and 45 a on only the side facing toward the garment 26 , and arm 42 z may include has a plurality of exits 44 z and 45 z on only the side facing toward garment 26 . The remainder of the arms 42 may have a plurality of exits 44 and 45 on both sides of each arm 42 so that the hanger-mounted garments 26 may be sprayed from both sides.
[0048] The liquid-exits 44 and air-exits 45 may be placed on the arms 42 so that the liquid or air exits the arms 42 in a downward direction. The shape of the arms may be any shape that allows the liquid-exits 44 and air-exits 45 to point downward. By way of example, the arms 42 may have a cross-sectional shape of an isosceles triangle with the two equal sides of the triangle facing downward, and with the liquid-exits 44 and air-exits 45 on the two downward facing sides of the triangle. The downward angle of the liquid or air may be any angle necessary to prevent the garments 26 from tangling and twisting, and to help smooth the garments 26 . By way of example, a downward angle between 40 degrees and 60 degrees may be used on the liquid-exits 44 and the air-exits 45 .
[0049] There are no specific requirements regarding placement of the liquid-exits 44 and air exits 45 relative to each other. That is, the liquid-exits 44 and the air-exits 45 may be placed in a horizontal line, may be placed with either on top of the other, or may be placed in any arrangement that allows liquid to exit the liquid-exits 44 , and allows air to exit air-exits 45 .
[0050] Returning to FIG. 1 , the manifold 40 may have one or more unthreaded guide holes 51 . The apparatus 10 may contain one or more guide post 50 . In one embodiment of the apparatus 10 , the number of unthreaded guide holes 51 is equal to the number to guide posts 50 . The guide post 50 may be a smooth post that runs in a vertical direction parallel to the rear wall 12 b . The guide post 50 may be inserted through the unthreaded hole 51 in the manifold 40 , and the manifold 40 may freely move along the length of the guide post 50 .
[0051] The manifold 40 may have one or more threaded screw holes 53 . The apparatus 10 may contain one or more screw posts 52 . In one embodiment of the apparatus 10 , the number of threaded screw holes 53 is equal to the number of the screw posts 52 . The screw post 52 may be a threaded post that runs in a vertical direction parallel to the rear wall 12 b . The screw post 52 and the threaded screw hole 53 may be threaded so that the threaded screw post 52 will turn inside the threaded screw hole 53 and, in turning, move the manifold 40 either up or down.
[0052] The screw post 52 may be moveably attached to a motor 54 . The motor 54 may be used to turn the screw post 52 in an alternating clockwise and counter-clockwise direction, thereby moving the manifold 40 up and down the screw post 52 . The motor 54 may be programmed via the control panel 28 so that the screw post 52 turns in one direction for varying lengths of time. The length of time that the screw post 52 turns in any one direction may be directly correlated to the length that the manifold 40 travels in any one direction. Thus, the screw post 52 may turn for such a length of time that the manifold 40 travels only part of the height of the cabinet 12 , or the entire length of the cabinet 12 . The control panel 28 may also provide a means for setting or programming the speed of the upward/downward motion, as well as the distance the manifold 40 travels in the upward/downward plane.
[0053] In one embodiment of the apparatus, one or more racks 70 may be attached to the bottom wall 12 f . The rack 70 may extend horizontally near the bottom of the cabinet 12 . Socks or other small items may be placed on the rack 70 and treated as described above.
[0054] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A garment processing apparatus is disclosed. The garment processing apparatus may include a hanger bar having a plurality of variable width notches, each of the variable width notches being capable of supporting a hanger with a garment thereon. The garment processing apparatus may also include a cabinet having an interior, the hanging bar being supported in the interior of the cabinet, wherein the cabinet is configured to process one or more of the garments. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims the benefit of U.S. patent application Ser. No. 10/396,619, filed Mar. 25, 2003, entitled “PLOW BLADE WITH WATER PASSAGEWAY.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] Many types of services are delivered to homes through conduits installed in relatively shallow underground trenches. These include telephone, television, natural gas, electricity, and drainage. These utilities are often installed with a plow. FIG. 1 illustrates an example installation of a utility 20 with a prior art plowing process. A plow 30 is attached to a prime mover, typically a tractor 10 . The tractor 10 propels the plow through the ground. The plow 10 is relatively narrow and will split the ground open with a sharpened steel blade. The utility line 20 is introduced into the ground through a chute 40 that is attached to and directly behind the blade. The chute 40 holds the ground open as the utility line 20 is being fed into the desired vertical position and places the utility line 20 into a horizontal position at the desired depth under ground.
[0004] An alternate configuration is illustrated in FIG. 2 where the utility line 20 is laid out on the ground behind its intended position and then the plow 30 is connected to one end. The plow is then pulled through the ground in order to pull the utility line 20 into the correct position. In this configuration there is no chute.
[0005] Depending on the desired depth, size of utility line, and the ground (soil) conditions (clay, sand, loam, etc.). This process may be slow and require a large amount of power from the tractor 10 to pull the blade/chute through the ground. To reduce this loading various efforts have been made to inject liquid to the plow and to the utility being installed to wet the ground.
[0006] In some past designs the liquid was water, ejected in the direction of travel of the plow blade, and at the edge of the plow blade, utilizing the water to assist in the cutting action required to slice the ground.
[0007] In other designs, useful for applications as illustrated in FIG. 2 , the liquid has been water directed to the area around the utility line being pulled through the ground to lubricate and reduce the frictional drag.
[0008] In still other designs water has been directed through long holes 36 drilled into the blade 34 of the plow 30 . Additional cross-drilled holes threaded to accept cooperating nozzles 38 are drilled near front edge 32 , as illustrated in FIGS. 3 and 4 . Water was then pumped into inlet fitting 37 to route water to the sides of the plow. This design has proven successful as the lubrication provided by the water significantly reduces the power necessary to pull the plow. However this requires complicated manufacturing processes, with the result that a wear item, the blade, becomes a relatively expensive component. There exists a need for a blade to provide this water distribution in a manner, that is less expensive to initially manufacture and to maintain.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates to a novel design for a plow blade which provides a fluid passage and points of fluid ejection which is produced with basic manufacturing processes allowing efficient production.
[0010] Another aspect of the present invention is a blade construction including a multiple component assembly. This provides the ability to rebuild a blade, replacing a portion of the blade that may be worn.
[0011] In another aspect of the present invention a process of ejecting a specific fluid at specific points along a plow blade the desirable characteristics are maximized, while the volume of ejected fluid is minimized. This method is adaptable in static plowing and vibratory plowing utilities. Lubricating the sides of the blade/chute that come into contact with the ground with fluid has been found to greatly reduce the amount of drag (friction).
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side view of a prior art tractor propelling a plow through the ground and installing a utility line that is being ejected through a chute attached to the plow;
[0013] FIG. 2 is a side view of a prior art tractor propelling a plow through the ground and installing a utility that is being pulled through the ground and attached to the plow;
[0014] FIG. 3 is side view of a prior art plow;
[0015] FIG. 4 is cross section of the prior art plow taken along line 4 - 4 as illustrated in FIG. 3 ;
[0016] FIG. 5 is a side view of one embodiment of a plow constructed in a manner of the present invention;
[0017] FIG. 6 is an isometric view of a portion of another embodiment of the plow of the present invention;
[0018] FIG. 7 is a cross-section taken along plane 7 - 7 as illustrated in FIG. 6 ;
[0019] FIG. 8 is an isometric view of a front edge section;
[0020] FIG. 9 is an isometric view of a portion of still another embodiment of the plow of the present invention;
[0021] FIG. 10 is a cross-section taken along plane 10 - 10 as illustrated in FIG. 9 ;
[0022] FIG. 11 is a side view of another preferred embodiment of a plow constructed in a manner of the present invention;
[0023] FIG. 11A is an enlarged view of the part marked 11 A in FIG. 11 ;
[0024] FIG. 12 is a cross-section taken along plane 12 - 12 as illustrated in FIG. 11 ;
[0025] FIG. 13 is cross-section taken along plane 13 - 13 as illustrated in FIG. 11 ;
[0026] FIG. 14 is a partial cross-section taken along plane 13 - 13 as illustrated in FIG. 11 : and
[0027] FIG. 15 is a view like FIG. 7 but showing an alternate embodiment with the void or channel formed in the blade instead of in the back of the front edge section.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring now to the drawings, like reference numerals designate identical or corresponding parts throughout the several views. The included drawings reflect the current preferred and alternate embodiments. There are many additional embodiments that may utilize the present invention. The drawings are not meant to include all such possible embodiments.
[0029] FIG. 5 illustrates a plow 100 constructed according to the principles of the present invention. Plow 100 consists of blade 110 , leading edge sections 120 , point 130 and a fluid tube 140 . Chute 40 is attached to the rear edge 114 of blade 110 , and is constructed to receive and guide utility line 20 from above the ground to the desired depth where it is oriented generally parallel to the ground surface. In other embodiments, the chute may be replaced by a puller adapted to hold a utility line that is being pulled through the ground, similar to the arrangement shown in FIG. 2 .
[0030] The blade 110 further includes a front edge 112 , a top end 116 and a bottom end 118 . The top end 116 includes apertures 117 which will serve as attachment points, to adapt to a power unit. Many different types of power units can be used in conjunction with the preset invention.
[0031] The bottom end 118 is adapted to support a variety of points 130 . The type of point to be installed may be dependent upon the soil conditions of a particular job.
[0032] A component of the present invention is the manner in which the components are assembled to form flow paths for fluid to exit the blade at controlled locations and with a controlled flow rate. The flow paths of this first embodiment illustrated in FIG. 1 are defined when the front edge 120 is attached to the blade 110 . FIG. 8 illustrates a void 124 in surface 122 of leading edge section 120 . Fluid tube 140 is adapted to travel in void 124 to transfer pressurized fluid from the top of plow 100 into the void 124 , and may be sealed with weld 152 illustrated in FIG. 6 . Other forms of sealing the connection between the tube 140 and the front edge sections 120 are possible, but are not illustrated herein as they are not a critical element of the present invention. Tube 140 has a top end 144 and a bottom end 146 and may extend into void 124 for any desired distance, as will be explained later.
[0033] As illustrated in FIGS. 6 and 7 the leading edge sections are attached to blade 110 with stitch welds 150 . Flow paths are defined by providing a small gap 154 between the front surface 112 of the blade and the rear surface 122 . The spaces between the stitch welds 150 results a flow path for the pressurized fluid, allowing fluid to pass from the void 124 , through the gap 154 between surfaces 122 and 112 , and out between the stitch welds 150 . In this manner, the location and length of the stitch welds 150 defines the location at which the fluid will exit the blade 110 . The gap 154 ( FIG. 7 ) between the surfaces 112 and 122 combined with the total amount of weld gap will define the volume at which the fluid will be ejected from the blade 110 at a certain fluid pressure.
[0034] FIG. 15 shows an alternate arrangement of the FIG. 7 structure, having the void or groove 224 formed in the front of the blade instead of having the void or groove 124 formed in the back of the leading edge section as shown in FIG. 7 .
[0035] The fluid pressure at a certain point along the blade's length will vary. If the tube 140 terminates at the top of blade 110 , the fluid pressure will be highest at that point and will decrease at points closer to the bottom. This is not ideal as there tends to be more resistance from the soils near the bottom of the blade, which requires the highest fluid pressure near that area. This is due to the types of soils typically encountered at lower depths. The surface soils typically include some percentage of organic matter, and higher percentage of air pockets: it is typically less dense. The soils encountered at points deeper can include the more difficult soils including clay. Thus there is an area, illustrated in FIG. 5 , as a critical high friction area. This is the area in which the fluid is most critical. In order to assure that the fluid is ejected most aggressively in this area tube 140 can be extended so that it terminates at a position towards the bottom of this critical high friction area, the tube end 146 is located near the bottom end 118 of the blade 110 . The fluid pressure in void 124 will be highest at the point the tube terminates. In this manner the volume of fluid at this point can be maximized.
[0036] In addition to varying the length of tube 140 , the number of leading edge sections 120 that are welded onto blade 110 can be varied to match the requirements of a specific job, including specific installation depths. The number of and location of the stitch welds can also be adjusted to tailor a plow 100 for a specific application. In this manner it is possible to provide a nearly infinite variety of configurations in an economic manner.
[0037] Another embodiment is illustrated in FIGS. 9 and 10 . In this configuration a manifold 160 is installed in between the blade 110 and the leading edge sections 120 . The manifold includes drilled holes 166 extending from a front side 164 to a rear side 162 , as illustrated in FIG. 10 . The drilled holes 166 intersect at the middle, and when the leading edges 120 are installed onto the front side 164 the drilled holes 166 will terminate at the void 124 in the leading edge 120 . In this manner a flow path is defined by the void 124 and the holes 166 which will allow fluid to be routed from tube 140 to nozzles 168 that are installed at the rear side 162 of the manifold 160 .
[0038] In this embodiment varying the nozzles 168 utilized in the assembly allows control of the flow rates and location of the fluid injection. The nozzles 168 can be replaced by plugs (not shown) if there are areas where fluid is not required, and the size of the nozzles 168 can be varied if the there are areas where extra flow is required. It provides a plow that can be modified using hand tools, without welding.
[0039] Still another preferred embodiment is illustrated in FIGS. 11 , 11 A, 12 and 13 . In this embodiment the fluid tube 140 has been located on the opposite side of blade 110 , the rear side 114 . As can be seen in FIG. 12 the fluid tube is located between the blade 110 and the chute 40 . In this configuration it is protected by plates 42 . The fluid tube includes an inlet fitting 142 at the top and travels to the bottom end 118 of blade 110 where it terminates at tube end 146 . The cross hatched portion shown in FIG. 11A represents a weld.
[0040] Tube end 146 is adapted to attach to a bottom end section 126 , as illustrated in FIG. 13 . Bottom end section 126 includes void 128 in the top side 127 as illustrated in FIG. 14 . Tube 140 includes a bend that allows it to enter into void. The tube 140 is then sealed by welding it to the bottom end section 126 and the blade 110 with weld 156 such that the fluid is forced into void 128 . The bottom end section 126 is also welded to the blade 110 at the locations where it contacts the blade 110 , thus sealing the void 128 .
[0041] Void 128 intersects void 124 at the bottom-front corner of blade 110 . At this point the fluid is transferred to void 124 and will flow along the front edge 112 of blade 110 . As described for the previous two embodiments, the fluid can then be allowed to travel to the edge of the blade and out to the soil either through a gap and spaces between stitch welds 150 , or through a manifold 160 between the front edge sections 120 and the blade 110 . FIGS. 11 and 12 illustrate the use of the stitch welds 150 and gaps 151 between stitch welds 150 . However, the manifold 160 would work equally well.
[0042] All the previously described embodiments provide a plow that can be tailored to provide fluid injection characteristics to match specific job requirements. The components are all manufactured with traditional manufacturing processes. The flow paths are defined by stacking together leading edge sections with flow voids, and welding or otherwise attaching them to a blade. This configuration provides appropriate function and provides an easily tailored configuration.
[0043] 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. | A plow blade having a fluid passageway and points of fluid ejection is produced with basic manufacturing processes allowing for efficient production. The blade construction has a multiple component assembly for providing the ability to rebuild a blade and replacing a portion of the blade that may be worn. In another aspect of the invention a process of ejecting a specific fluid at specific points along a plow blade the desirable characteristics are maximized, while the volume of ejected fluid is minimized. This method is adaptable in static plowing and vibratory plowing utilities since lubricating the sides of the blade/chute that come into contact with the ground with fluid has been found to greatly reduce the amount of drag (friction). | 4 |
PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent application Ser. No. 10/438,097 (allowed), filed May 15, 2003, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to telecommunication network implementations; and in particular to a method and system for routing incoming communications in a communications network.
BACKGROUND
[0003] As a whole, the teachings of the prior demonstrate that it has largely been pre-occupied with other priorities within this niche. For instance, much art is devoted to varied apparatus for allowing one wireless phone to share two (or more) telephone numbers (or SIMs) or conversely for allowing one SIM card to be shared between two masters (as between a cellular radiotelephone and multi-mode satellite radiotelephone as detailed for instance in U.S. Pat. No. 6,141,564 to Bruner, et al. entitled method of sharing a SIM card between two masters).
[0004] And similarly, other art has likewise been devoted to switching between multiple SIM cards within a wireless phone as to maximize time-of-day discounts (consider for instance European Patent Application 1098543 by Fragola, F.), or as to lower roaming costs (consider U.S. patent application Ser. No. 20020154632 by Wang, Yung-Feng et al.) and so forth.
[0005] Other inventions, as UK Patent No. 2375261 to Hiltunen, M. entitled transfer of SIM data between mobile computing devices, are devoted to ‘acquiring’ the identification information contained within the SIM card of one mobile phone and transferring it to another, thereby creating a manner of ‘virtual’ SIM, thereby obviating for physically transferring SIM cards between wireless devices and the corresponding lag and down-time associated with such.
[0006] Still further art as U.S. Pat. No. 6,466,804 to Pecen, et al. entitled method and apparatus for remote multiple access to subscriber identity module, details a method and apparatus for remote multiple access to services of a subscriber identity module (SIM) card by multiple subscriber devices in a GSM system. The crux of the subject matter delineated thereof deals with the scenario whereby multiple wireless devices use a single SIM. Whereas the invention of present seeking the protection of Letters Patent effectively enables multiple independent SIMs (e.g. with individual IMSIs) to appear as a single SIM for the purpose of providing telephony services via a macroscopic (GSM) carrier.
[0007] Indeed, we submit that there remains nothing in the prior art which intimates or anticipates the particular network based solution presented herein.
REFERENCES CITED
[0008]
[0000]
U.S. Patent Application
20020154632
October, 2002
Wang, et al.
370/389
U.S. Pat. No. 6,466,804
October, 2002
Pecen, et al.
455/558
U.S. Pat. No. 6,141,564
October, 2000
Bruner, et al.
455/558
Foreign Patent Document(s)
2375261
November, 2002
GB
1098543
May, 2001
EP
[0009] Other References
[0010] GSM 03.40, Digital cellular telecommunications system (Phase 2+); Technical realization of the Short Message Service (SMS)
[0011] GSM 09.02, Mobile Application Part (MAP) specification
[0012] GSM 03.90, Digital cellular telecommunications system (Phase 2+); Unstructured Supplementary Service Data (USSD)—Stage 2
SUMMARY
[0013] The method and system allowing for one mobile phone number (MSISDN) to be associated with a plurality of wireless devices (Multi-SIM) described herein provides the requisite art for a wireless subscriber to present/utilize one phone number (Mobile Station Integrated Services Digital Network (MSISDN) Number) across a plurality of wireless devices (and their inherent, requisite SIMs (Subscriber Identity Modules)). Effectively, the invention of present seeking the protection of Letters Patent enables multiple independent SIMs (e.g. with individual IMSIs (International Mobile Station Identifiers)) to utilize the same phone number (MSISDN) for the purpose of providing telephony services via a macroscopic (GSM) carrier. The collective effect of the invention with respect to the telecommunication services which can be offered via a plurality of wireless devices will be characterized as the ‘Multi-SIM’ service.
[0014] The art has been articulated such that, even across a multiplicity of wireless devices, when originating a telecommunication, a common phone number (MSISDN) is always displayed.
[0015] The mobile subscriber in question may choose which wireless device (and its associated SIM) s/he wishes to receive telecommunications upon in the preferred embodiment. In particular, various non-limiting manifestations of the invention may optionally direct Voice, SMS (Short Message Services), MMS (Multi-Media Message Services), MWI (Message Waiting Indicator) services towards different wireless devices and their associated SIMs. Optional manifestations of the invention limits the number of simultaneous telecommunications activity which emanate from the plurality of devices associated with the Multi-SIM service. Further optional manifestations of the invention permits the automated redirection of telecommunications services (e.g. call delivery and location retrieval) based on a pre-configured settings or the detection of activity from the plurality of wireless device or active polling to determine the status of the plurality of wireless devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates a typical, non-limiting embodiment of the system level architecture employed in the disclosure of present;
[0017] FIG. 1A details a non-limiting call-flow of the subscriber registration sequence for mobile originated voice telecommunications of the method and system allowing for one mobile phone number (MSISDN) to be associated with a plurality of wireless devices.
[0018] FIG. 1B represents a non-limiting call-flow detailing the means through which mobile terminating SMS or MMS traffic is managed by the method and system allowing for one mobile phone number (MSISDN) to be associated with a plurality of wireless devices.
[0019] FIG. 1C represents a non-limiting call-flow detailing the means through which the location of a mobile station may be retrieved.
[0020] FIG. 1D represents a non-limiting call-flow detailing the means through which an indication of the unsuccessful nature of a SMS delivery attempt will be relayed to a SMS-C. FIG. 1D also represents a non-limiting call-flow detailing the means through which the unavailability of a given mobile station may be provided to a given SMSC for subsequent SMS delivery attempts.
[0021] FIG. 1E represents a non-limiting call-flow detailing the means through which an indication of availability (for the purpose of receiving Short Messages) may be relayed to a SMS-C.
[0022] FIG. 1F represents a non-limiting call-flow detailing the means through which unstructured supplementary service (USSD) message handling is accommodated.
[0023] FIG. 1G represents a non-limiting call-flow detailing the means through which supplementary service message handling is accommodated.
[0024] FIG. 1H represents a non-limiting call-flow detailing the means through which call delivery to a wireless device is accommodated.
DETAILED DESCRIPTION
[0025] In the following description, for purposes of explanation and not limitation, specific details are set forth, such as particular embodiments, elements, interfaces, hardware configurations, data structures, software flows, techniques, etc. in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well known methods, devices, and elements are omitted so as not to obscure the description of the present invention with unnecessary detail.
[0026] With reference to FIG. 1 , the essential logic 70 B for the method and system allowing for one mobile phone number (MSISDN) to be associated with a plurality of wireless devices ('Multi-SIM') 70 , provides the core Mobile Application Part (MAP) intercept function 70 A establishing devices against the Multi-SIM Mobile Station Integrated Services Digital Network (MSISDN) in the network such that outgoing traffic is seen to originate from the Multi-SIM MSISDN. The Multi-SIM computer program product 70 also intercepts incoming traffic to the Multi-SIM MSISDN and directs it to the nominated primary device ( 1 A, 1 B, 1 C as applicable) for that traffic type. Practitioners and other honorable members skilled in the art will recognize that the primary device need not be bound to one (1) of three (3) selections and may exceed such limitations to the state of the art.
[0027] A non-limiting, illustrative list of such MAP messages which will ordinarily be encountered by the Multi-SIM method and system include the messages, including the various parametric attributes, as prescribed in the GSM TS 09.02, ETSI TS 100 974, and 3GPP TS 29.002 Mobile Application Part (MAP) specifications as amended from time to time.
[0028] Wireless subscribers who obtain the high-level service delineated herein from their respective telecommunications carriers and/or network operators will have a defined number of devices ( 1 A, 1 B, 1 C and so forth); each device is provisioned in the HLR (Home Location Register) 50 and in the Multi-SIM database 70 C. An individual MSISDN is associated with each device ( 1 A, 1 B, 1 C) in the HLR 50 but is not used outside of the HLR 50 and Multi-SIM inventions 70 .
[0029] FIGS. 1A , 1 B, 1 C, 1 D, 1 E, 1 F, 1 G, and 1 H have been included as variants of FIG. 1 to ease and facilitate the instruction of the art, and should be interpreted as aiding and helping to achieve such ends. The labels of FIG. 1 are therefore incorporated by reference.
[0030] With reference now to FIG. 1A , the mobile and/or wireless device ( 1 A, 1 B, 1 C) (among others and as applicable), is activated (‘turned on’). After a given wireless device completes any programmed self-check procedure, it will initiate the registration sequence via the applicable air-interface as well as the serving MSCNLR 30 A per steps 100 A. The serving MSCNLR 30 A, as per the usual operational processes of a GSM network, normally forwards the MAP Update Location message to the HLR 50 associated with the IMSI‘x’ of the mobile device's SIM. For the purpose of the disclosed invention, the MAP Update Location message will instead be forwarded to the Multi-SIM invention 70 at step 100 B. Those skilled in the art shall recognize that there are a variety of mechanisms by which the MAP Update Location message can be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 (Signaling System 7 ) network and the associated translation capabilities of the serving MSC/VLR 30 A. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for IMSI‘x’ from the perspective of the serving MSCNLR 30 A.
[0031] After receiving the MAP Update Location message, the Multi-SIM invention 70 will store the addressing information of the MSC/VLR 30 A associated with IMSI‘x’. The Multi-SIM invention will also retrieve the address of the HLR 50 associated with IMSI‘x’ and forward the MAP Update Location message to the appropriate HLR 50 via the SS7 network at step 100 C. An optional manifestation of the Multi-SIM invention 70 will initiate a MAP version negotiation sequence (not shown) as described in GSM 09.02 (and similar specifications) if the MAP version number of the received message at step 100 B is greater than that currently supported by the HLR 50 associated with IMSI‘x’. Those skilled in the art will recognize that there are a number of well understood message sequences associated with the MAP version negotiation procedure and that the intent of such a such a procedure is to ensure that subsequent messages received from network elements such as the serving MSC/VLR 30 A are set to a MAP version level no higher than the MAP version level supported by the HLR 50 associated with IMSI‘x’. The MTP (Message Transfer Part) and SCCP (Signaling Connection Control Part) of the MAP Update Location message forwarded to the HLR 50 at step 100 C will be modified by the Multi-SIM invention 70 so that the Multi-SIM invention will appear as a VLR from the perspective of the HLR 50 . Those skilled in the art will recognize that the HLR 50 utilizes received VLR and MSC addressing information in the MAP layer of the Update Location message to invoke service screening criteria as defined by GSM specifications. For example, a VLR or MSC address associated with a given service provider's ‘home’ network may be accorded different service attributes relative to the VLR and MSC associated with a ‘foreign network. To that end, an optional manifestation of the invention will map the VLR and MSC addressing information received in the MAP layer of the Update Location message to a predefined subset of alternative VLR and MSC addresses in order to invoke an appropriate set of service attributes for the subscribers associated with the Multi-SIM service. Those skilled in the art will recognize that for the aforementioned optional manifestation of the invention that the HLR 50 will have to be configured (typically via translation tables) to apply a specific set of service attributes given the predefined subset of alternative VLR and MSC addresses.
[0032] Still in reference to FIG. 1A , the HLR 50 will retrieve the subscriber's profile using IMSI‘x’ as the index key using established processes commonly implemented by HLR vendors. The subscriber's profile will include, among other subscribed service attributes, the MSISDN‘x’ associated with IMSI‘x’. The HLR 50 will in turn initiate a MAP Insert Subscriber Data sequence, containing the subscribed attributes associated with the subscriber's profile and MSISDN‘x’, which will be forwarded to the Multi-SIM invention 70 via the SS7 network at step 110 A. Those skilled in the art shall recognize that the HLR 50 will direct the MAP Insert Subscriber Data sequence to the Multi-SIM invention 70 via the SS7 network by virtue of the received MTP and SCCP addressing information received at step 100 C.
[0033] Still in reference to FIG. 1A , the MAP Insert Subscriber Data message is received from the HLR 50 by the art of the Multi-SIM invention 70 (specifically 70 A) at 110 A. Using said IMSI‘x’ as an index key, the Primary MSISDN is retrieved (not shown) from an internal database/table 70 C (via 70 B). An optional manifestation of the invention will store the status of the wireless device associated with IMSI‘x’ in the application memory or internal database 70 C for the purpose of applying optional routing procedures for outgoing and incoming as noted in a subsequent portion of this disclosure. Yet another optional manifestation of the invention will store selected attributes associated with Intelligent Network (IN) services in application memory or internal database 70 C. Those skilled in the art will recognize that there are a variety of IN services which are defined by various specifications which serve the similar purposes without diluting the intent and scope of the present invention including those associated with CAMEL (Customized Applications for Mobile Network Enhanced Logic) and CS-1 (Capability Set 1) as well as derivations thereof.
[0034] Still in reference to FIG. 1A , the Multi-SIM invention 70 will generate an MAP Insert Subscriber Data message where the MSISDN‘x’ received from the HLR 50 will be replaced by the Public MSISDN retrieved from the Multi-SIM internal database 70 C. The Multi-SIM invention 70 will forward the MAP Insert Subscriber Data message to the serving MSCNLR 30 A via the SS7 network at step 110 B. Those skilled in the art will recognize that a characteristic of the invention is that the MAP Insert Subscriber Data received by a MSCNLR 30 A always contains the Public MSISDN regardless of which IMSI‘x’ (and corresponding SIM and wireless device) was activated.
[0035] Still in reference to FIG. 1A , after the serving MSCNLR 30 A processes the information received via the MAP Insert Subscriber Data message received at step 110 B, the serving MSCNLR 30 A generates and forwards a MAP Insert Subscriber Data acknowledgement message to the Multi-SIM invention 70 at step 120 A. At step 120 B, the Multi-SIM invention 70 will forward a MAP Insert Subscriber Data acknowledgement message to the HLR 50 modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 120 A as required. For example, the Primary MSISDN will be replaced by MSISDN‘x’. The HLR 50 will receive the MAP Insert Subscriber Data message and generate an MAP Update Location acknowledgement message using established processes commonly implemented by HLR vendors. The HLR 50 will forward the MAP Update Location acknowledgement message to the Multi-SIM invention at step 130 A. The serving MSCNLR 30 A will receive the MAP Update Location acknowledgement message and initiate an appropriate confirmation message to the wireless device 1 ‘x’ at step 130 B. At step 130 C, the serving MSCNLR will complete the registration sequence with the mobile station.
[0036] Still in reference to FIG. 1A , a mobile originated call may then be established at step 140 A. The MSCNLR 30 A will initiate a call to the intended destination address via the Public Switched Telephone Network (PSTN) using the procedures prescribed using the ISDN User Part (ISUP) protocol at step 140 B. A characteristic of the disclosed invention is that the Calling Party Number information associated with the call establishment procedure will be set to the primary MSISDN forwarded to the serving MSCNLR 30 A by the Multi-SIM invention 70 at step 110 B.
[0037] Still in reference to FIG. 1A , those skilled in the art will recognize that a similar sequence will be invoked for GPRS (General Packet Radio Service) registration scenarios. In particular, a characteristic of the disclosed invention is that the Primary MSISDN identifier will be associated with a given IMSI‘x’ for the PDP (Packet Data Protocol) Context Activation establishment procedure.
[0038] Still in reference to FIG. 1A , an optional manifestation of the Multi-SIM invention 70 may selectively screen outgoing call attempts by utilizing procedures associated with IN services. In particular, an IN message (e.g. CAMEL INITIAL_DP) originated from the serving MSCNLR 30 A will indicate a call attempt being made by a mobile station 1 A, 1 B, 1 C. The Multi-SIM invention 70 may invoke screening criteria based on the destination and source address information contained in the IN message. The Multi-SIM invention 70 may also invoke incremental screening criteria based on the state of a given mobile device (associated with IMSI‘x’) as stored in the Multi-SIM invention database 70 C (not shown). For example, the Multi-SIM invention 70 may use screening criteria to limit the number of simultaneous calls or to redirect calls to an alternative destination address. The Multi-SIM invention 70 will instruct the serving MSCNLR 30 A via an appropriate IN message (e.g. CAMEL CONTINUE or CAMEL CONNECT or CAMEL CANCEL) as to the appropriate course of action based on the screening criteria. Those skilled in the art will recognize that the optional manifestation of the Multi-SIM invention 70 will provide functionality commonly associated with a Service Control Point (SCP). Those skilled in the art will also recognize that there are a variety of IN protocols which are defined by various specifications which serve the similar purposes without diluting the intent and scope of the present invention including those associated with CAMEL and CS-1 (Capability Set 1) as well as derivations thereof. Another optional manifestation of the Multi-SIM invention 70 may act as an intermediation gateway between the serving MSCNLR 30 A and a given Service Control Point (not shown) for the purpose of ensuring the seamless support of IN services supported by the Service Control Point (not shown).
[0039] Now with reference to FIG. 1B , where the respective Short Message (SM) stored in SMS-C 40 remains to be delivered. Those skilled in the art will recognize that the Short Message may also consist of a Multi-Media or voice-mail alerting message. The SMS-C will generate and forward a MAP SEND-ROUTING-INFO-FOR-SM (SRI for SM) message which will be directed to the Multi-SIM invention. Those skilled in the art shall recognize that there are a variety of mechanisms by which the MAP SRI for SM message can be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 network and the associated translation capabilities of the SMS-C 40 . Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for a given Primary MSISDN from the perspective of the SMS-C 40 .
[0040] Still in reference to FIG. 1B , the Multi-SIM invention 70 will retrieve the subscriber's service profile using the Primary MSISDN as the index key from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, information pertaining to the specific routing preferences for Short Message as well as Multi-Media Messages and Voice-Mail alerts as the case may be. The Multi-SIM invention will generate and forward a MAP SRI for SM response message to the SMS-C 40 at step 210 . The MAP SRI for SM response message will contain information so that the SMS-C will consider the Multi-SIM invention as the serving MSC for the purpose of Short Message delivery. For example, the Network Node Number parameter will contain an identifier which will uniquely identify the Multi-SIM invention as the serving MSC for the purpose of Short Message delivery. Those skilled in the art will recognize that the MAP SRI for SM response message at step 210 will contain other parameters so that the SMS-C will be able to continue processing the delivery of the Short Message. For example, the MAP SRI for SM message will contain an IMSI value which can be selected from the set of IMSI‘x’ associated with the Primary MSISDN or set to a configurable range of values. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto VLR from the perspective of the SMS-C 40 .
[0041] Still in reference to FIG. 1B , at step 220 , the SMS-C will attempt delivery of the message by generating and forwarding a MAP MT-FORWARD-SHORT-MESSAGE (MT FSM) message to the Multi-SIM invention 70 . At step 230 , the Multi-SIM invention will determine the appropriate mobile device (as identified by the IMSI‘x’ associated with a given SIM and mobile device respectively) to receive the Short Message based on a number of factors including the source address contained in the MT FSM message as well as the nature of the message (e.g. short message or alert). Note that the Multi-SIM invention 70 may use a variety of techniques in order to determine the appropriate mobile device based on either programmatic methods (for example, the last device that registered may be used to forward all short messages) or based on pre-established criteria as provided by the subscriber (for example, the subscriber may send Short Messages and alert messages to different devices based on the relative capabilities supported on each device). The programmatic methods may in turn be affected by the state of each device (e.g. whether a given mobile device is engaged in a call or registered). Those skilled in the art will recognize that a variety of techniques may be used in order to determine the destination mobile device without diluting the intent and scope of the present invention. A characteristic of the disclosed invention is that telecommunication services can be selectively terminated to the plurality of mobile devices based on a number of programmatic techniques as well as pre-configured routing criteria.
[0042] Still in reference to FIG. 1B , at step 230 , the Multi-SIM invention will generate and forward a MT FSM to the serving MSC/VLR 30 A associated with the IMSI‘x’ of the selected mobile station, modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 230 as required. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto SMS-C from the perspective of the serving MSC/VLR 30 A. At step 240 , the short message will be delivered to the mobile station 1 A, 1 B, 1 C (among others and as applicable) associated with IMSI‘x’. At step 250 , a MAP MT FSM response message containing an indication of the successful or unsuccessful nature of the delivery attempt will be initiated by the serving MSC/VLR 30 A and forwarded to the Multi-SIM invention 70 . At step 260 , the Multi-SIM invention 70 will generate and forward a MT FSM response to the appropriate SMS-C 40 , modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 250 as required.
[0043] Now with reference to FIG. 1C , a Location Client 80 will initiate a location retrieval request via an Application Programming Interface (API) at 300 A which will include a number of parameters including but not limited to the Primary MSISDN and a transaction identifier. In lieu of a Primary MSISDN, the Location Client may provide a pseudonym which can be correlated to the Primary MSISDN. The purpose of the transaction identifier being to uniquely correlate a given request with other messages which may be received asynchronously including, but not limited to, a confirmation response. Practitioners skilled in the art shall recognize that a variety of object oriented application programming interfaces (e.g. Common Object Request Broker Architecture (CORBA) or Extensible Markup Language (XML)) may be used.
[0044] Still in reference to FIG. 1C , at step 300 B, the Gateway Mobile Location Centre (GMLC) 81 will receive the location retrieval request. The GMLC 81 will initiate a MAP ANY-TIME-INTERROGATION (ATI) sequence to the Multi-SIM invention 70 . Those skilled in the art shall recognize that there are a variety of mechanisms by which the MAP ATI message can be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 network and the associated translation capabilities of the GMLC 81 . Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for IMSI‘x’ from the perspective of the GMLC 81 . Those skilled in the art will recognize that the functionality of the GMLC is generally defined by a variety of specifications including GSM 03.71 and 3GPP 23.071 as amended from time to time and that modifications to the capabilities of the GMLC as prescribed by the noted specifications does not dilute the intent and scope of the present invention. A characteristic of the disclosed invention is that the location of a given mobile terminal can be retrieved without sending messages to the HLR 50 . Those skilled in the art will recognize that the Multi-SIM invention 70 effectively emulates certain capabilities associated with the HLR for the purpose of retrieving the location associated with a mobile station.
[0045] Still in reference to FIG. 1C , at step 300 C, the Multi-SIM invention 70 will retrieve the subscriber's service profile using the Primary MSISDN as the index key from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, information pertaining to the specific preferences for location retrieval, the last known location of the device based on previous location retrieval attempts, as well as the current list of active or registered devices (as identified via the IMSI‘x’ identifier associated with a given SIM and mobile device respectively). The Multi-SIM invention 70 will determine the appropriate mobile device (as identified by the IMSI‘x’ associated with a given SIM and mobile device) for the purpose of a location query based on a number of factors including the source address contained in the MAP ATI message. The Multi-SIM invention 70 may use a variety of techniques in order to determine the appropriate mobile device for the location query based on either programmatic methods (for example, the last device that registered) or based on pre-established criteria as provided by the subscriber (for example, the subscriber may rank order a number of devices to be located in preferential order). The programmatic methods may in turn be affected by the state of each device (e.g. whether a given mobile device is engaged in a call or registered). Those skilled in the art will recognize that a variety of techniques may be used in order to determine the mobile device for a location query without diluting the intent and scope of the present invention. The Multi-SIM invention 70 will initiate a MAP PROVIDE-SUBSCRIBER-Info (PSI) message towards the appropriate serving MSC/VLR 30 A based on the selected mobile station (which is associated with a given IMSI(x)) modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 300 B as required. Upon receipt of the MAP PSI message, the serving MSC/VLR 30 A will retrieve the location of the mobile station. The mechanisms of retrieving the location of the mobile station are generally prescribed by a variety of specifications including GSM 03.71 and 3GPP 23.071 as amended from time to time.
[0046] Still in reference to FIG. 1C , at step 310 A a MAP PSI response message will be initiated by the serving MSC/VLR 30 A which will contain the location of the mobile terminal. The MAP PSI response message will be forwarded to the Multi-SIM invention 70 . At step 310 B, the Multi-SIM invention 70 will generate and forward a MAP ATI response to the GMLC 81 , modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 310 A as required. An optional manifestation of the Multi-SIM invention 70 will store the location of mobile station (associated with IMSI‘x’) in the internal database/table 70 C (not shown). At step 310 C, the GMLC 81 will provide the location information to the Location Client 80 via the API. Those skilled in the art will recognize that an optional manifestation of the Multi-SIM invention 70 may abbreviate the location retrieval attempt by providing location information associated with previous location attempts. This will effectively result in steps 300 C and 310 A being bypassed. The retrieval and provision of stored location information is governed by programmatic control and there are a number of procedures and conditions (for example, time based methods) which may be applied to abbreviate the location retrieval process.
[0047] Now with reference to FIG. 1D , where a SMS delivery report associated with a SMS delivery attempt is to be forwarded to the appropriate SMS-C. At step 400 A, a MAP MT-FORWARD-SHORT-MESSAGE (MT FSM) response message containing an indication of the unsuccessful nature of the delivery attempt will be initiated by the serving MSC/VLR 30 A and forwarded to the Multi-SIM invention 70 . Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto SMS-C from the perspective of the serving MSC/VLR 30 A based on the intermediation of registration and SMS delivery sequences previously described. At step 400 B, the Multi-SIM invention 70 will generate and forward a MT FSM response to the appropriate SMS-C 40 , modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 400 A as required.
[0048] Still in reference to FIG. 1D , at step 410 , the SMS-C 40 A will initiate a MAP REPORT-SM-DELIVERY-STATUS which will contain a number of parameters including the Primary MSISDN and Service Center address and which will be forwarded to the Multi-SIM invention 70 . Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for a given Primary MSISDN from the perspective of the SMS-C 40 A. To that end, the Multi-SIM invention 70 will emulate the capabilities associated with a HLR 50 for the purpose of setting and maintaining the Message Waiting Data file for the Primary MSISDN. The Message Waiting Data file can be implemented via a variety of mechanisms without diluting the intent and scope of the present invention. For example, the Message Waiting Data file can be stored as a multi-element data element in the Multi-SIM database 70 C (as indexed by the Primary MSISDN). Those skilled in the art will recognize that the intent of the Message Waiting Data file in the HLR, among other functions, is to record the address of SMS-Cs for subsequent notification once a given mobile station is deemed active (registers). At step 420 A, the Multi-SIM invention 70 will initiate a MAP REPORT-SM-DELIVERY-STATUS response message to the SMS-C 40 A indicating that the SMS-Cs address has been stored. At step 420 B, the SMS-C 40 A may provide an indication of the unsuccessful delivery attempt to the Message Center 41 A.
[0049] Still in reference to FIG. 1D , at step 430 A, a Message Center 41 B may attempt to deliver a Short Message to the a given subscriber as identified by the Primary MSISDN. At step 430 B, the SMS-C 40 B will generate and forward a SRI for SM message which will be directed to the Multi-SIM invention 70 . Those skilled in the art shall recognize that there are a variety of mechanisms by which the MAP SRI for SM message can be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 network and the associated translation capabilities of the SMS-C 40 . The Multi-SIM invention 70 will retrieve the subscriber's service profile and the Message Waiting Data file using the Primary MSISDN as the index key from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, information pertaining to the specific routing preferences for Short Message as well as Multi-Media Messages and Voice-Mail alerts as the case may be. As the Message Waiting File will indicate that the mobile station is not active/registered, the Multi SIM platform 70 will generate and forward a MAP SRI for SM response message to the SMS-C 40 B at step 440 which will indicate that the subscriber is absent (typically by sending the User Error parameter to ‘Absent Subscriber_SM’)
[0050] Still in reference to FIG. 1D , at step 450 , the SMS-C 40 B will initiate a MAP REPORT-SM-DELIVERY-STATUS which will contain a number of parameters including the Primary MSISDN and Service Center address and which will be forwarded to the Multi SIM platform 70 . At step 460 , the Multi-SIM invention 70 will initiate a MAP REPORT-SM-DELIVERY-STATUS response message to the SMS-C 40 B indicating that the SMS-Cs address has been stored.
[0051] Now with reference to FIG. 1E , which illustrates the intercept of the MAP READY FOR SM operation generally used by the MSC/VLR 30 A if a subscriber, whose message waiting flag is active in the VLR, has re-established radio contact with the network or has memory available. At step 500 , the MSC/VLR 30 A generates MAP READY FOR SM message which is forwarded to the Multi-SIM invention 70 . Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for a given IMSI‘x’ from the perspective of the MSC/VLR 30 A. The MAP READY FOR SM message will contain several parameters indicating if the mobile subscriber is present or if the mobile station has memory. At step 510 , the Multi-SIM invention will generate and forward a MAP READY FOR SM response message to the MSC/VLR 30 A indicating that the message at step 500 has been received and processed successfully.
[0052] Still in reference to FIG. 1E , the Multi-SIM invention 70 will retrieve the subscriber's service profile using the IMSI‘x’ as the index key from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, information pertaining to the specific routing preferences for Short Message as well as Multi-Media Messages and Voice-Mail alerts as the case may be. The service profile will contain the Primary MSISDN associated with IMSI‘x’ which will in turn be used to index the Message Waiting Data elements. Based on the information retrieved, the Multi-SIM invention will determine which SMS-C should be contacted. Those skilled in the art will recognize that the Multi-SIM invention may use a variety of techniques in order to determine the appropriate SMS-C based on the information contained in the internal database/table 70 C (not shown). In particular, the Multi-SIM invention may determine that a SMS-C may not be contacted based on the routing preferences prescribed by the subscriber. Alternatively, the Multi-SIM invention may determine that several SMS-Cs (not shown) should be contacted. At step 520 A, the Multi-SIM invention will generate and forward a MAP ALERT-SERVICE-CENTRE (Alert SC) to the selected SMS-C 40 A (or SMS-Cs (not shown)) indicating that a given subscriber (as identified by the Primary MSISDN) is ready to receive Short Messages. At step 520 B, the SMS-C may alert Message Centers to the effect that a given subscriber may receive Short Messages.
[0053] Still in reference to FIG. 1E , at step 530 B, the SMS-C 40 A will generate and forward a MAP Alert SC response message to the Multi-SIM invention 70 indicating that the MAP Alert SC message was received and processed successfully. At this point in time, the SMS-C 40 may initiate the short message delivery mechanisms as described earlier in the text associated with FIG. 1B .
[0054] Still in reference to FIG. 1E , those skilled in the art will recognize that other mechanisms including the registration process described in FIG. 1A may invoke the MAP Alert SC sequence described at step 520 A.
[0055] Now with reference to FIG. 1F , USSD MAP messages are typically routed to and from the USSD Application via the serving MSC/VLR and HLR using the methods, operations, and protocols specified in GSM 03.90 and GSM 09.02 as amended from time to time. An optional manifestation of the invention provides an USSD-based subscriber interface to change default routing preferences of Multi-SIM subscribers. The Multi-SIM invention will also permit subscribers and network operators to make configuration changes via a (web-based) provisioning interface.
[0056] Still with reference to FIG. 1F , at step 600 , a subscriber may invoke an Unstructured Supplementary Service Data (USSD) service by keying in a USSD short code (e.g. *XX#). This will invoke a USSD Message (e.g. MAP PROCESS_UNSTRUCTURED_SS_REQUEST (PUSSR)) which will be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 network and the associated translation capabilities of the serving MSC/VLR 30 A. At step 610 , the Multi-SIM invention 70 may recognize that the USSD short code (as provided via the USSD String parameter) matches a prescribed code associated with the invocation of a feature of the Multi-SIM service. Example services include modifying the routing behavior of the Multi-SIM service for received voice or messaging traffic or obtaining information pertaining to the current settings of the Multi-SIM invention for the subscriber. At step 610 , the Multi-SIM invention initiates a MAP USSD response message. The MAP USSD response message may contain text which indicates that the requested feature was invoked successfully or requested information pertaining to the status of the Multi-SIM service. At step 610 , the MSC/VLR will relay the information to the mobile station per the processes described in GSM 03.90 and GSM 09.02.
[0057] Still with reference to FIG. 1F , at steps 620 A, 620 B, 630 , a USSD message which is not associated with a Multi-SIM service or feature is propagated to the USSD Based Application 90 via the Multi-SIM invention 70 and HLR 50 . At step 620 B, the Multi-SIM invention modifies the SCCP, TCAP, and MAP layers of the message relative to that received at step 620 A as required. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for IMSI‘x’ (or the Primary MSISDN) from the perspective of the MSC/VLR 30 —and that the Multi-SIM invention will appear as a defacto MSC/VLR for IMSI‘x’ (or MSISDN‘x’) from the perspective of the HLR 50 . At steps 630 , 640 A, 640 B, an USSD response message initiated from the USSD Based Application 90 and is propagated to the serving MSC/VLR 30 A via the HLR 50 and Multi-SIM invention 70 . At step 640 B, the Multi-SIM invention modifies the SCCP, TCAP, and MAP layers of the message relative to that received at step 640 A as required. At step 640 B, the MSC/VLR will relay the information to the mobile station per the processes described in GSM 03.90 and GSM 09.02.
[0058] Now with reference to FIG. 1G , Supplementary services (e.g. call forwarding services) are typically modified (in order to activate, deactivate, register, erase, or check the status of supplementary services as the case may be) via MAP messages between the MSC and the VLR and between the VLR and the HLR using the methods, operations, and protocols specified in GSM 09 . 02 as amended from time to time. At step 700 , a subscriber may invoke a command via the Man Machine Interface (MMI) of his/her mobile terminal in order to modify a supplementary service. This will invoke a Supplementary Service MAP message (e.g. MAP ACTIVATE SS) which will be forwarded to the Multi-SIM invention 70 using the inherent capabilities of the SS7 network and the associated translation capabilities of the serving MSC/VLR 30 A. The Multi-SIM invention 70 will retrieve the subscriber's service profile from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, the complete range of terminal information associated with the subscriber—including the entire suite of IMSI‘x’ and MSISDN‘x’ information associated with the subscriber. At steps 710 , 730 , and 750 the Multi-SIM invention will propagate the appropriate Supplementary Service MAP message to the HLR(s) 50 associated with a given IMSI‘x’ for each device 1 A, 1 B, 1 C as applicable (in particular, each IMSI‘x’ may be associated with a different HLR). Practitioners skilled in the art will recognize that the number of devices need not be bound to one (1) of three (3) selections and may exceed such limitations to the state of the art. At steps 720 , 740 , and 760 the HLR(s) will generate and initiate appropriate Supplementary Service MAP response messages which will be forwarded to the Multi-SIM invention 70 . At step 770 , once the Multi-SIM invention 70 has received confirmation that the required supplementary service command has been carried out successfully, the appropriate Supplementary Service MAP response message will be generated and forwarded to the Serving MSC/VLR 30 A. At step 770 , if one of the responses from the HLR indicates an unsuccessful attempt, a Supplementary Service MAP response message indicating an unsuccessful attempt will be provided to the serving MSC/VLR 30 A. An optional manifestation of the invention may roll-back the settings associated with a given supplementary service by invoking the complementary Supplementary Service command (e.g. a DEACTIVATE SS message to counter a prior ACTIVATE SS message) (not shown). The optional manifestation of the invention will retrieve the status of a given Supplementary Service setting via the MAP INTERROGATE_SS message (not shown) prior to invoking the subscriber command at steps 710 , 730 , 750 .
[0059] Now with reference to FIG. 1H , at step 800 A, a call will be received by the Gateway MSC 30 C from the PSTN 95 . At step 800 B, the Gateway MSC 30 C will generate and forward a MAP SEND_ROUTING_INFORMATION (SRI) message to the Multi-SIM invention 70 . The Multi-SIM invention 70 will retrieve the subscriber's service profile using the Primary MSISDN as the index key from an internal database/table 70 C (not shown). The service profile will contain, among other attributes, information pertaining to the specific preferences for call delivery, the last known location of the device based on previous location retrieval attempts, as well as the current list of active or registered devices (as identified via the IMSI‘x’ identifier associated with a given SIM and mobile device respectively). The Multi-SIM invention 70 may use a variety of techniques in order to determine the appropriate mobile device (as identified by the IMSI‘x’ associated with a given SIM and mobile device) for call delivery based on either programmatic methods (for example, the last device that registered) or based on pre-established criteria as provided by the subscriber (for example, the subscriber may rank order a number of devices for call delivery in preferential order). The programmatic methods may in turn be affected by the state of each device (e.g. whether a given mobile device is engaged in a call or registered). At step 800 C, an optional manifestation of the Multi-SIM invention will confirm the status of the selected mobile station by initiating a MAP PROVIDE-SUBSCRIBER-Info (PSI) message to the serving MSC/VLR 30 A. At step 810 , the serving MSC/VLR 30 A will provide a MAP PSI response message containing the status of the mobile station. Depending on the nature of the status information received, the Multi-SIM invention may select an alternative mobile station and confirm the status of the alternative mobile station (not shown) (in effect, steps 800 C and 810 will be repeated). This process will continue until a suitable mobile station (as identified by IMSI‘x’) is determined to be available for the purpose of receiving a call. At step 820 , once a suitable mobile station is selected, the Multi-SIM invention will generate a MAP SRI message and forward it to the HLR. At step 830 , the HLR 50 will generate a MAP PROVIDE_ROAMING_NUMBER (PRM) message and forward it to the Multi-SIM invention 70 . At step 840 , the Multi-SIM invention 70 will forward the MAP PRM message to the serving MSC/VLR 30 A modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 830 as required. At step 850 , the serving MSC/VLR 30 A will generate and forward a MAP PRM response message containing the roaming number to the Multi-SIM invention 70 . At step 860 , the Multi-SIM invention 70 will forward the MAP PRM response message to the serving HLR 50 modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 850 as required. At step 870 A, the HLR will generate and forward a MAP SRI response message to the Multi-SIM invention 70 containing the roaming number. At step 870 B, the Multi-SIM invention 70 will forward the MAP SRI response to the Gateway MSC 30 C modifying the MTP, SCCP, TCAP, and MAP layers of the message relative to that received at step 870 A as required.
[0060] Still in reference to FIG. 1H , the Gateway MSC 30 C will establish a call to the serving MSC/VLR 30 A via the PSTN using the routing number received at step 870 B. A characteristic of the disclosed invention is that the incoming calls can be selectively prioritized based on a number of attributes including the state of each mobile device (as identified by IMSI‘x’) and the prescribed routing preferences of the subscriber. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto HLR for a Primary MSISDN or IMSI‘x’ from the perspective of the Gateway MSC 30 C and the serving MSC/VLR 30 A respectively. Those skilled in the art will recognize that the Multi-SIM invention 70 will appear as a defacto Gateway MSC and serving MSC/VLR for a MSISDN‘x’ and IMSI‘x’ from the perspective of the HLR 50 .
[0061] Still in reference to FIG. 1H , an optional manifestation of the Multi-SIM invention 70 may act as an intermediation gateway between the serving Gateway MSC 30 C and a given Service Control Point (not shown) for the purpose of ensuring the seamless support of IN services supported by the Service Control Point (not shown). | A method and system for routing incoming communications in a communications network are provided. The network comprises a plurality of network elements. An addressable number is associated with a plurality of communications devices each identified by a unique identifier. A communication addressed to a communications device is received at a network element, the communication comprising the addressable number. A subscriber service profile associated with the addressable number is retrieved at a discrete network element, where an appropriate communications device for delivery of the incoming communication based on pre-established criteria in the subscriber service profile is determined. An identifier of the appropriate communications device is forwarded from the discrete network element to the network element. The communication is transmitted to the appropriate communications device. The subscriber service profile comprises preferences for delivery of communications, and a list of communications devices that are at least one of active and registered. | 7 |
This application is a continuation of application 08/191,398, filed Feb. 2, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to hockey apparatus, and more particularly pertains to a new hockey goal arrangement wherein the same is arranged to provide for a hockey goal structure relative to use in the playing of miniature hockey.
2. Description of the Prior Art
Miniature hockey typically played indoors is arranged to employ various game pucks such as spheres, cylinders, and the like typically formed of various materials such as softened polymerics and the like. Even bottle caps and ping pong balls may be employed as a game puck.
Prior art has heretofore employed various structure to provide for a hockey goal, such as indicated in U.S. Pat. Nos. 3,979,120; 3,840,228; 3,698,715; as well as U.S. Pat. No. 4,018,443.
The present invention attempts to overcome deficiencies in the prior art by providing a goal structure for use in the playing of miniature hockey including a housing with a cushion mounted to a top wall of the housing to accommodate an individual thereon.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of hockey goal structure now present in the prior art, the present invention provides a hockey goal arrangement wherein the same sets forth a housing arranged to accommodate an individual thereon in play of miniature hockey. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new hockey goal arrangement apparatus and method which has many of the advantages of the prior art listed heretofore and many novel features that result in a hockey goal arrangement apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.
To attain this, the present invention provides a goal structure for use in the playing of miniature hockey includes a housing having side walls, with at least one of the side walls including an opening, and the opening including a cushion perimeter to minimize uncontrolled deflection of the hockey projectile, with a cushion mounted to a top wall of the housing to accommodate an individual thereon.
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 of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
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 hockey goal arrangement apparatus and method which has many of the advantages of the prior art listed heretofore and many novel features that result in a hockey goal arrangement apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.
It is another object of the present invention to provide a new hockey goal arrangement which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new hockey goal arrangement which is of a durable and reliable construction.
An even further object of the present invention is to provide a new hockey goal arrangement 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 hockey goal arrangements economically available to the buying public.
Still yet another object of the present invention is to provide a new hockey goal arrangement 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.
It is yet a further object of the present invention to provide a new hockey goal arrangement having side walls, with at least one of the side walls including an opening, and the opening including a cushion perimeter to minimize uncontrolled deflection of an impacting hockey projectile.
Still yet another object of the present invention to provide a new hockey goal arrangement having side walls and a top wall, with at least one of the side walls including an opening, and with the top wall having a cushioned surface to accommodate an individual thereon.
These together with other objects of the invention, along with the various features of novelty which characterize 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 had to the accompanying drawings and descriptive matter in which there is 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 an isometric illustration of the invention.
FIG. 2 is a front elevation view of the invention.
FIG. 3 is a cross sectional view, taken along the lines 3--3 of FIG. 1 in the direction indicated by the arrows.
FIG. 4 is an isometric partial view indicating adhesive mounting of the cushion layer onto the top wall of the hockey goal housing.
FIG. 5 is an isometric illustration of a modified housing structure.
FIG. 6 is an orthographic view, taken along the lines 6--6 of FIG. 5 in the direction indicated by the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1-6 thereof, a new hockey goal arrangement embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the hockey goal arrangement 10, as set forth in the FIGS. 1-4, includes a housing 11 having a top wall 12, a first side wall 13 spaced from a second side wall 14, and a first end wall 15 spaced from a second end wall 16. The walls 12-16 cooperate to define a substantially rectangular enclosure which may be positioned upon a ground surface suitable for playing the game, such surfaces including carpet, tile, and the like.
A game puck 17, such as a sphere, a cylinder, or the like, is provided in cooperation with an L-shaped hockey stick 18, whereupon an individual positioned upon a cushion pad 19 mounted upon the top wall 12 attempts to deflect the game puck from entering through a first side wall entrance opening 20 having a first side wall cushion perimeter portion 21 that is provided to prevent uncharacteristic deflection of the game puck which may result in an unintentional striking of associated players.
FIG. 4 indicates that an adhesive interface 22 is oriented between the cushion pad 19 and the top wall 12 for adherence of the cushion pad to the top wall.
In play, two of the goal arrangements 10 may be positioned a predetermined distance apart, whereby opposing players may be situated on top of respective goals in a kneeling or sitting position. The puck 17 may then be placed on the ground, whereby opposing players, each utilizing hockey stick 18, strike the puck and attempt to project it through the side wall entrance opening 20 of the opposing player's goal arrangement 10 to score a predetermined number of points.
FIGS. 5 and 6 illustrate a modified hockey goal arrangement 10a, wherein a modified housing 11a includes a modified second end wall 16a to include a second end wall goal opening 23, as well as a second end wall cushion perimeter portion 24 to provide for scoring of goals through a plurality of entrance openings 20, 23. If desired, the remaining end wall 15 may be provided with a similar entrance opening to provide an entrance opening through a plurality of the walls of the housing 11a.
As best illustrated by the cross section in FIG. 6, the hockey goal arrangement 10a utilizes a rotary plate 25 which includes a rotary plate cushion 26 secured thereon. A rotary plate shaft 27 forming an integral part of the rotary plate 25 is rotatably directed through the top wall 12 and fastened within the housing 11a by a shaft fastener 29 to mount the rotary plate thereto. Bearing members 28 positioned within an annular bearing groove 30 between the rotary plate 25 and the top wall 12 permit a rotation of the rotary plate 25 and the associated rotary plate cushion 26. This arrangement provides for the re-orientation of an individual onto the housing 11a without necessitating movement of that individual relative to the plate cushion 26.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention 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 goal structure for use in the playing of miniature hockey includes a housing having side walls, with at least one of the side walls including an opening, and the opening including a cushion perimeter to minimize uncontrolled deflection of the hockey projectile, with a cushion mounted to a top wall of the housing to accommodate an individual thereon. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Appl. 60/742,442, filed Dec. 5, 2005.
TECHNICAL FIELD
[0002] The present invention relates to a novel attachment system for lengthening garments. In particular, the novel attachment system includes a decorative embellishment component which facilitates lengthening the garment while providing the wearer with a customized and/or personalized look.
BACKGROUND OF THE INVENTION
[0003] Clothing is generally mass produced in a variety of sizes. Most casual clothing can be purchased in a range of sizes and requires no alteration. Although generally acceptable, this system of permanent alteration does not very well address the different contexts in which a pair of slacks are worn. For example, different styles of shoes may be worn that effectively change the desired length of the slacks (i.e., high heels may require longer slack legs than flat shoes). In that case, the slack legs are either made for heels (and therefore are too long for flat shoes), or they are made for flat shoes (and therefore too short for heels). Custom tailoring each pair of slacks for each pair of shoes, while possible, is not very economical.
[0004] Furthermore, clothing for children quickly gets outgrown as the child gets older. Alternatively, children's clothing can be purchased with “room to grow” and thus, hemming, altering, or folding up sleeves, pant legs, etc., is often used, but the clothing does not fit properly and the look is shoddy.
[0005] Various devices are used in conjunction with clothing. For example, it is known to attach a safety pin to a piece of clothing to hold it up. However, such pins are not very attractive and can be difficult to attach if multiple folds or thick fabric is involved. Also, tie tacks are known, which serve primarily to hold a tie close to the shirt of the wearer. Of course, a wide variety of buttons and pins have been attached to clothing for decoration or identification of the wearer.
[0006] Convertible garments are well know in the art. Thus, U.S. Pat. No. 4,232,402 discloses a convertible jacket where extensions can be secured to a short jacket by zipper-type slide fasteners to lengthen the jacket into a short coat with one extension or a full coat with two extensions. U.S. Pat. No. 4,766,613 discloses shorts which may be converted to trousers by the addition of leg portions. Hook and pile material (hereinafter Velcro®) is used to secure the leg portions to the shorts. U.S. Pat. No. 698,205 and U.S. Pat. No. 2,274,382 both disclose that extensions can be added to skirts or slips, the extensions being secured thereto by passing a ribbon or string through mating loops in adjacent pieces. U.S. Pat. No. 4,975,987 discloses Velcro® for removably attaching various ornamentation to clothing, whereas U.S. Pat. No. 6,178,680 discloses for the same purpose stems which pass through the clothing and female segments which receive the stems. U.S. Pat. No. 5,088,128 discloses a drop-down cuff for pants legs or sleeves, which cuffs are held in their raised positions by Velcro® pads or by stitching. U.S. Pat. No. 5,173,965 discloses a convertible skirt where the lower portion is provided with crystal beads or buttons which may be secured to an ornamental loop braid at the bottom of the upper portion or short skirt. U.S. Pat. No. 5,774,892 is similar to U.S. Pat. No. 4,766,613, but further discloses that a short sleeve shirt may be converted to a long sleeve shirt by using Velcro® strips. U.S. Pat. No. 5,894,043 discloses a hem holding device for the temporary shortening and raising of a hem line of an article of clothing by the wearer of that clothing. U.S. Pat. No. 6,408,438 discloses an adjustable length garment where the tubular additions may be secured to an adjacent upper portion by a zipper. This patent also discloses that an ornamental strip having braids 48 (which may include beads) may be zippered to the bottom tubular portion. In all of the prior art designs where an upper portion of a garment is lengthened by the addition of a lower tubular portion, both the upper and lower portions have been provided with attachment structure. In the prior art cited above there is a lack of teachings of separate attachments for lengthening a sleeve, skirt, or pants leg, which attachments can be used with any garment.
[0007] U.S. 2005/0044610 teaches that a garment may be provided with convertible ornamentation. U.S. Pat. No. 6,684,544 teaches that a badge or name holder may be worn on a shirt or the like, where the badge is provided with a strip of magnetic material, and separate magnets may be used to hold the badge in place.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] It is the object of the present invention to provide a simplified and safe attachment mechanism for lengthening garments.
[0009] Another object of the present invention is to provide a lengthening attachment that can be used for garment ornamentation and accessorizing which can be utilized on virtually any article of clothing or garment. The present invention offers real flexibility with virtually unlimited application.
[0010] The decorative attachment of the invention comprises a first component, attachment means that securely but removably fastens to the hem of a garment; and a second component, the decorative means, that attaches to the attachment means for providing an ornamental and/or decorative attachment. The decorative attachment of the invention provides a means for lengthening the hem of a garment, while at the same time being ornamental in nature.
[0011] The decorative attachment of the invention can be comprised of any known configuration and material that will securely fasten it to a garment without damaging the garment and allow for the attachment of a decorative means. The attachment means and decorative means can be integrated and formed in one single unit or can be comprised of separate units whereby the attachment means is secured to the hem of the garment and the decorative means is secured to the attachment means. In this configuration, a multitude of different ornamental means could be attached to the attachment means depending on the mood of the wearer.
[0012] In one embodiment of the invention there is provided a decorative attachment which is intended primarily for lengthening garments. Every parent has had the experience of buying clothes for their children only to find that their child's pants are too short only a few month later. In addition, many long legged girls have difficulty finding slacks which are long enough. Thus, adding length to a garment that is too short is desirable to increase the useful length of a garment. In addition, adding length to a garment may also add a decorative element and style to the garment. The attachment of this invention will serve the purpose of adding length to pants or any other garment where length is an issue. The present invention can consist of a decorative attachment and any other element that assists the attachment in attaching or adhering to the garment without any type of permanent alteration to the garment.
[0013] The decorative attachment can comprise many different elements and/or shapes and still be within the spirit of the present invention. The attachment can comprise a series of hook/clip type fasteners or a support strip that attach to the hem of a garment without alteration to the garment. The attachment can include an elastic material that attaches to the hem of a garment. The attachment can include magnetic strips for securing the attachment to the hem of a garment without alteration to the garment. The attachment can include individual clips or any other means which can be devised for securing the attachment to the hem of a garment without alteration to the garment.
[0014] While the primary use of the decorative attachment is for lengthening a garment, the attachment has multiple uses, for example it can comprise a long strip for attachment to material objects such as a house, lamp, etc. for securing decorative items.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 shows an embodiment of this invention secured to a pants leg to both lengthen the pants leg and to provide an ornamental appearance.
[0016] FIGS. 2 and 3 are front and rear views, respectively, of the embodiment shown in FIG. 1 .
[0017] FIGS. 4 and 5 are rear and side views of the fastener of this invention.
[0018] FIG. 6 is a section taken generally along the line 6 - 6 in FIG. 1 .
DETAILED DESCRIPTION
[0019] With reference first to FIG. 1 , the attachment of this invention, which is indicated generally at 10 , is shown secured to the lower edge of a pants leg 12 . While a pants leg is illustrated, it should be noted that the attachment of this invention could be secured to sleeves, skirts, etc. Each attachment of the illustrated embodiment will include a first band of material 14 and a plurality of j-shaped fasteners indicated generally at 16 ( FIGS. 4 and 5 ). Each j-shaped fastener has two integral generally parallel spaced apart portions, a long portion 16 . 1 and a short portion 16 . 2 , the short portion being provided with a barb 16 . 3 . A bight portion 16 . 4 interconnects the two generally parallel portions 16 . 1 and 16 . 2 . The fastener 16 is made of a resilient material, such as nylon or polypropylene. The long portion is provided with two spaced apart apertures 16 . 5 and 16 . 6 for the receipt of a thread 18 ( FIG. 3 ) used for securing the fasteners 16 to the first band of material 14 .
[0020] As shown in FIGS. 2 and 3 the band of material is generally rectangular before it is applied to the garment. However, the band of material may be tubular with the ends 14 . 1 and 14 . 2 being sewn together or joined together in any conventional manner. When used with a pants leg there is an advantage of not having the ends 14 . 1 and 14 . 2 joined together as frequently the heel of a shoe might contact the trailing edge of the material. This will not happen if there is a gap in the material, and the gap will not be noticeable when the user of the attachment is viewed from the front. While in most cases the material will be of a cloth fabric, it is possible that the band of material may be formed of other flexible materials. Thus, the outer first band 14 that carries the fasteners 16 may be made of cloth fabric, plastic, metal fabric, or any other pliable material that can be made into a band or ribbon and offer support. The clips can be made of metal, plastic, or any other medium that has enough tension to keep the attachment secured to the garment
[0021] As can be seen from FIGS. 1, 2 , and 6 ornaments 20 provided. As illustrated, the ornaments consist of a plurality of short strings of beads. However, other forms of ornamentation may be used. The ornaments may be secured to either the top edge of the first band, or to a second band 22 , which second band also functions to conceal the top edge of the ornamentation when it is secured to the top edge of the first band 14 . The second band and the ornamentation may be attached to the first band by sewing, by means of an adhesive, mechanical means or any other means of attachment.
[0022] While a uniform first band 14 of material is illustrated, it can be in sections, which sections may be of different materials. The band 14 can be made of any type of material including not only fabric, but also fur, beading, leather, lace, feathers, etc.
[0023] The decorative attachment can be applied to a hem to lengthen any type of garment or any other item where fasteners can be safely and firmly attached, even if the item in question does not need the attachment for function. The decorative attachment will be offered in different forms and styles. Differences in style or design can be attributed to age group and sex.
[0024] Therefore, it should be clear that the decorative attachment of the present invention provides a simple, safe and secure mechanism for lengthening and decoration clothing. It is within the scope of the present invention for the attachment to take any shape and comprise any material so long as it securely attaches to the hem of a garment. The ornamentation 20 can take any shape and size and can be comprised of any known material.
[0025] While a preferred form of this invention has been described above and shown in the accompanying drawings, it should be understood that applicant does not intend to be limited to the particular details described above and illustrated in the accompanying drawings, but intends to be limited only to the scope of the invention as defined by the following claims. In this regard, the term “means for” as used in the claims is intended to include not only the designs illustrated in the drawings of this application and the equivalent designs discussed in the text, but it is also intended to cover other equivalents now known to those skilled in the art, or those equivalents which may become known to those skilled in the art in the future. | A novel attachment for lengthening garments, the attachment including a first band of material and fasteners carried by the first band of material for grasping the hem of the garment without alteration to the garment. The novel attachment may include a decorative embellishment component which provides the wearer with a customized and/or personalized look. | 0 |
RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 09/899,906 filed Jul. 6, 2001, which is a continuation-in-part of Ser. No. 09/250,504 filed Feb. 16, 1999 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to obstacle monitoring pipeline pigs used in checking the interior of a pipeline for obstacles which might impede the movement of subsequently used pipeline inspecting devices or which exceed industry guidelines.
A number of caliper pigs are on the market that provide detection of anomalies inside pipelines. They are usually expensive to produce and operate. These existing pigs monitor all restrictions along a pipeline regardless of the size of the anomalies. They normally collect a significant amount of data that requires interpretation by a technician or computer programs. This type of caliper pigs is represented, for instance, by the disclosure of U.S. Pat. Nos. 4,953,412 and 5,088,336 (both Rosenberg et al.) and also by U.S. Pat. No. 3,755,908 (VerNooy). The disclosures of the above patents are incorporated herein by reference.
U.S. Pat. No. 4,481,816 (Prentice) describes a caliper pig provided with a monitoring arrangement comprising a substantially circular array of detecting, portions which deform upon contact with the interior surface of the pipeline and remain deformed to provide an indication that the minimum radial distance has been exceeded. Viewed from the standpoint of the present invention, the device disclosed is of a relatively complex structure and allows only a single use of the detecting portions. Also, if a relatively large deformity is encountered prior to reaching a somewhat smaller deformity, the latter may be undetected.
U.S. Pat. No. 4,227,309 (Jones) describes a pipeline pig which includes a flexible disc at a foremost part of the body. The disc is fixedly secured to the body of the pig and is provided with strain gauges which transmit deformations of the disc to electrical impulses to show which portion of the disc has been deformed by an abnormality within the pipeline. The use of the strain gauges renders the overall structure of the flexible disc complex thus increasing the cost of replacement of a damaged disc. Furthermore, the strain gauges are too sensible for the rough working environment of a damaged pipeline and may therefore produce false readings. The piezo electric strip was found working as a microphone; it recorded all vibrations and one could not differentiate between the vibrations and restrictions. Vibrations of the body and thus of the disc are often encountered in use of the pig. There is no backup system which would indicate, at least roughly, the location of an abnormality in case of failure of the electronic system. The location of the disc at the foremost end of the body is disadvantageous as distorted readings of the deformation of the disc by an abnormality occur at a straight portion of the pipeline and in bends of the pipeline. Also, the disc being fixedly secured to the body, it cannot maintain the same angular clock position as it inevitably changes such position with the rotation of the pig about its longitudinal axis. Such rotation may occur when an abnormality is encountered by the guiding cups. The device therefore is not capable of showing the clock position of an abnormality instantly recorded.
U.S. Pat. No. 4,299,033 (Kiley et al.) presents a calipering tool for oil wells or the like applications. It operates with a plurality of feelers which are in a constant contact with the pipe of a well. The tool is of a complex structure. While it may be useful in calipering wells, it is not suitable for applications where only major deformities of the pipe are required to be discovered to avoid damage to a subsequently used caliper pig. Also, the tool of this reference is raised and lowered by means of a suspension cable which cannot be used in pipeline calipers as they often have to travel long distances of tens of miles.
U.S. Pat. No. 4,443,948 (Reeves) describes a pig for monitoring the internal surface profile of a pipeline. It is provided with a plurality of sensors which are in constant contact with the inner surface of the monitored pipeline. A complex system is required to compare output signals from the sensors with an expected value and reference signal generated when they differ by more than a predetermined amount.
U.S. Pat. No. 4,457,073 (Payne) shows a pipeline pig with sensing means capable of monitoring small changes in the internal configuration of a pipeline. A complex mechanism is used to monitor dragging effect to which an elastomeric cap is submitted upon encountering an obstacle. A major obstacle would most likely destroy or at least damage the mechanism used to record the deformities, as the radial cup is in a constant contact with the interior of the monitored pipeline.
U.S. Pat. No. 4,098,126 (Howard) is provided with a plurality of sensors disposed about the circumference of a resilient holding cup. A spring system forces the sensors against the inside of the pipeline. The device is suitable for monitoring relatively small deformities but would become damaged if a major or sharp deformity is encountered. It is of relatively complex structure with a number of flat spring elements constantly pressing the sensors against the pipeline.
U.S. Pat. No. 4,091,678 (Potter) shows a device for detecting dents or out of round conditions of a buried pipeline. The pig contains two concentric rings. The outer ring is sized to accurately fit the inspected pipeline. It carries on its inner surface electrical contacts adapted to co-operate with contacts provided on the outer surface of the inner ring to close an electric circuit when the outer ring is deformed radially inwardly. The device may be suitable for detecting minor anomalies of the cross-section of the pipeline. Larger deformities would destroy or at least damage the system of coaxial rings.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an obstacle monitoring or caliper pig which would be of a simple structure permitting relatively low manufacturing costs, monitoring only major obstacles of a predetermined minimum magnitude and providing a simple operation.
In general terms the invention provides a caliper pig for detecting an obstruction in a pipeline, having an elongated body including a front end and a rear end and comprising carrying guide rings at said front and rear ends for supporting the body in a coaxial sliding engagement with the interior of the pipeline and driving the body through the pipeline, the front end first, using the flow of fluid in the pipeline, said body further carrying a coaxial, generally disc-shaped, detector operatively associated with transfer mechanism including a converting member movable relative to the body responsive to a generally axial force to transmit a mechanical impulse developed at the detector to activate and to deactivate an electrical signal producing device housed in said body, wherein
(I) said detector has an outer diameter smaller than the inside diameter of the pipeline to define therewith a generally annular void having a predetermined radial clearance;
(ii) said transfer mechanism is operatively disposed between a flexing portion of the detector and said converting member to transmit changes in the form of the deflector to said axial force.
In a particularly preferred embodiment, the detector comprises a resilient disc shaped member mounted on said slider and having a scratch recording layer bonded to a front face of the member turned toward said front end of the pig bonded to a scratch recording layer. The scratch recording layer possesses resiliency sufficient for the layer to follow deformation of the resilient detector and return of the detector to a non-deformed state. Furthermore, the scratch recording layer it has smoothness and softness sufficient for the layer to become and remain scratched when the detector engages an anomaly of a predetermined minimum radial magnitude and when the detector returns to said non-deformed state. Thus, after passage of the pig through the pipeline, the front face of the disc indicates the nature and magnitude of anomaly or anomalies encountered during the passage by way of scratched portions of the recording layer.
In another aspect, the invention provides, for use in a pipeline caliper pig including a body provided with support and drive members for sliding engagement with the interior of the pipeline to drive the body coaxially through the pipeline by the flow of fluid in the pipeline:
an elastomeric, generally disc-shaped detector compatible with said body for securement thereto, said ring comprising;
(a) a first face, an axially opposed second face, and a circular circumferential edge portion having a predetermined diameter smaller than the inside diameter of the pipeline;
(b) said first face having a forward surface possessing:
(I) resiliency sufficient to follow resilient deformations of the ring and to return, with the ring, from a deformed to a non-deformed state;
(ii) smoothness and softness sufficient to become and remain scratched by obstacles in the pipeline as the detector,; secured to said body, advances through the pipeline.
Yet another embodiment of the present invention is generally characterized by a combination, wherein a detector, particularly for use in a caliper pig for detecting an obstruction in a pipeline, is provided. It comprises, in general terms, a resiliently deformable body including a securement portion adapted to be secured to a support, and a flexing portion spaced from the securement portion and adapted to flex relative to said support when subjected to a force in a predetermined direction;
said body comprising
a resiliently deformable first member having a leading face and a trailing face and
a resiliently deformable second member having a leading face and a trailing face;
the trailing face of said first member being turned toward the leading face of said second member; the distance between the trailing face of said first member and the leading face of said second member being at a predetermined minimum when the body is in a relaxed state;
signal generating means disposed in said flexing portion of the body and remote from said securement portion thereof,
said signal generating means comprising:
a first generating element secured to said first member; and
a second generating element secured to said second member in an alignment with the first generating element when the body is in a relaxed state;
said first and second generating elements being adapted to co-operate to emit a first signal when the elements are close to each other, and a second signal, distinct from said first signal, when the elements are remote from each other due to a difference between the degree of flexing between the first and second deformable members.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail with reference to the attached simplified, diagrammatic, not-to-scale drawings, it being understood that while these are presently preferred embodiments, they may be modified to a substantial degree without departing from the gist of the present invention. In the drawings:
FIG. 1 is a section view of the pig of the present invention shown as it passes through a section of a pipeline; and
FIG. 2 is a sectional view taken along the section line 11 — 11 of FIG. 1;
FIG. 3 is a view similar to that of FIG. 1 but showing another, preferred, embodiment of the pig of the present invention;
FIG. 4 is a sectional view of a detector as a replaceable part of the pig shown in FIG. 3;
FIG. 5 is a partial section view similar to FIG. 3 but showing only a detail of an alternative structure of the detector attachment to the body of the caliper pig;
FIG. 6 is a section view similar to FIG. 4 but showing the alternative structure of the detector used in the embodiment of FIG. 5;
FIG. 7 is a section view of yet another embodiment of the pig of the present invention;
FIG. 8 is a view taken in the direction of arrows 8 — 8 of FIG. 7;
FIG. 9 is a view of mutual arrangement of a sensor spring relative to the detector surface;
FIG. 10 is a view of an exemplary embodiment of the structure of a sensor spring of the present invention;
FIG. 11 is a diagrammatic, out-of-scale side view of yet another embodiment of the present invention;
FIG. 12 is a detail of the embodiment of FIG. 11 showing the sensor in an operative position when encountering a relatively small irregularity of the pipeline;
FIG. 13 is a view similar to that of FIG. 13 showing the sensor at the initial stage of encountering a larger irregularity than that shown in FIG. 12; and
FIG. 14 is a view similar to that of FIG. 13 at the stage following the initial contact of FIG. 13, with the sensor in an actuated state.
DETAILED DESCRIPTION
The first embodiment of the inventive caliper pig is provided with supporting elastomeric rings 10 , 11 , 12 connected to a centrally disposed cylindric body one after the other and comprised of a front ring 10 , an intermediate ring 11 and a rear ring at the back end of the pig.
A segmented, generally disk-shaped resilient member has a number of segments separated from each other along a generally radial line of separation 14 b . The member 14 is concentric with the support or guide rings 10 - 12 . It is fixedly secured to the body 20 between the front support ring 10 and the intermediate support or guide ring 11 . The resilient member 14 has a smaller outside diameter than the inside diameter of the pipeline 15 . The member 14 thus defines an annular void between its outer surface and the inner surface of the pipeline wall. The member 14 may be provided with a scratch recording leading face not shown in FIG. 1 and 2 but described later with reference to FIGS. 3 and 4.
The radial width of the void 21 is predetermined and depends on the operational requirements of particular application. It generally correspond to the maximum tolerable size, usually specified by the operator of the pipeline, of restrictions at the inner surface of the pipeline 15 . As a rule, the width of the void 21 presents about 10% of the inner diameter of the pipeline. A number of links 22 are pivotally connected with their rear ends to front faces of the segments 14 a of the resilient member 14 at its flexing portion which is radially beyond the flanges or the like members securing the disc 14 to the body 20 . The front ends of the same links 22 are pivotally connected to a slider 16 which is slidable in axial direction on the body 20 . When the resilient member is relaxed (as shown in FIG. 1 ), it holds the slider 16 at a predetermined resting position relative to the body 20 such that the first and second switches 17 , 18 are inactive.
The pig is propelled through the pipeline by a pressure differential at the front and rear ends of the pig, driving the pig from the left to the right of FIG. 1 . If an obstacle is encountered at the wall of the pipeline 15 , which is radially in excess of the width of the void 21 , the respective segment 14 a of the resilient member 14 is deflected by a force which is proportional to the size of the obstacle. Since the pig continues its movement, the segment 14 a of the resilient member 14 pulls the slider 16 , via the respective link 22 , to the left of FIG. 1 . The slider 16 is displaced a predetermined distance which is sufficient to activate the mechanism (not shown in detail) of the first switch 17 . As a result, emission of an appropriate signal takes place indicating that a relatively small obstacle, for instance, a dent in the wall of pipeline 15 has been encountered. Eventually,;the resilient member runs over the obstacle and returns back to the relaxed state thus returning the slider 16 back to the resting position where both switches 17 , 18 are again inactive.
If the obstacle encountered is more substantial, e.g. a partly closed valve, the resilient member 14 is displaced along the body 20 to a greater axial distance, activating the second switch 18 to provide a signal of the more substantial anomaly having been encountered.
A deformable barrier ring 19 made, for instance, of a malleable, relatively thin sheet metal, has the same diameter as the resilient member 14 . It is mounted at the rear end of the pig. Its purpose is to double check the function of the switches 17 , 18 . If any of the switches malfunctions and fails to indicate an anomaly, then such anomaly inevitably deforms the ring 19 thus providing information that the switch triggering mechanism malfunctioned. If no signal of an obstacle is received and after the completed run of the pig C the check ring 19 is not deformed, then indeed no obstacle was encountered in the inspected section.
Whenever the pig detects a restriction, time may, be recorded and saved for analysis at the end of the run. Information recorded may be fed to a computer!that will correlate the time the restrictions were encountered with other tracking information and pipeline geographic position. The positioning will only provide the operator with an approximation of the restriction location. This, however, is a sufficient information as the state of any given pipeline section is normally monitored and anomalies recorded by the pipeline owner or user.
As the pig is designed to only detect large restrictions that are associated with partially closed valves or some other fitting problems, or exceed industry guidelines, the limited accuracy will still provide the operator with sufficient information to determine if there are any excessive restrictions and, if a restriction has been identified, to eliminate it before running other, more sensitive caliper pigs, and ensure that the pipeline is maintained within the industry guidelines.
Turning now to the embodiment of FIG. 3, an improved and particularly preferred embodiment of the pig is shown in an operative position, received in a pipeline 30 . The pig comprises two resilient guide rings 31 , 31 a , one at the front, the other at the rear of the pig body 32 which has a generally tubular configuration. The front guide ring 31 is secured to the body 32 by a holder plate 33 pressed against the ring 31 by an end cap 34 . The rear guide ring 31 a is secured to the body 32 by holder plates 35 , 36 pressed against the rear end of the body 32 by an end cap 37 . As is well known, at least the front guide ring 31 engages the pipeline 30 in a sealing fashion to provide a pressure differential caused by the flow of a fluid through the pipeline 30 , driving the pig from the left to the right of FIG. 3 .
The front end cap 34 is provided with a threaded inner portion 38 which is engaged in a tubular sleeve 39 fixedly secured, for instance by welding or adhesively, to the body 32 near the front end thereof. The inner portion 38 of the end cap abuts against a plug 40 provided with a front O-ring 41 and a rear O-ring 42 , to seal the hollow tubular interior 43 . The tubular interior 43 houses a switch mechanism or the like electro-mechanical device.
The slider 44 of the embodiment shown has a cylindric surface integrally formed with a radially outwardly projecting rear flange or shoulder portion 45 . A resilient disc shaped detector 46 abuts with its back end against the flange portion 45 . The detector 46 is retained generally in abutment with the flange portion 45 on the slider 44 by a retainer clip 47 received in an appropriate groove machined in the surface of the slider 44 . As in the first embodiment described, the portion of the disc 46 radially outwardly of the shoulder portion 45 is generally referred to as a flexing portion of the detector. The slider comprises a known switch mechanism. Such switch mechanism would typically have a magnet or magnets on the inside of the slider 44 and detector switch or switches secured to the body 32 . Many obvious modifications of the electric signal producing arrangement can be used without departing from the invention. Therefore, the sleeves 44 or 16 are to be considered merely as preferred embodiment of what is generally referred to as a transfer mechanism including a converting member (e.g. the sleeve) movable relative to the body 32 or 20 responsive to a generally axial force to transmit a mechanical impulse developed at the detector 46 to activate or deactivate an electrical signal producing device.
The outer diameter (OD) of the detector 46 is about 20% smaller than the inside diameter (ID) of the pipeline 30 . For instance, if the ID of the pipeline 30 is 10″, then the OD of the detector 46 is about 8″. The detector 46 is composed of a resilient disc, in the embodiment shown a polyurethane disc 50 . The front face of the disc 50 is provided with a scratch recording layer, in the embodiment shown, a lead layer 51 which is bonded to the disc 50 so that the two form a generally integrally formed structure. According to the present invention, the thickness of the lead layer 51 is selected such that it has flexibility sufficient to follow deformation of the disc 50 when the detector 46 encounters an anomaly in the pipeline. At the same time, the flexibility of the layer 511 provides that once the anomaly is cleared, the layer 51 follows the disc 50 bouncing back to the original, relaxed position. The lead layer 51 is preferred in the present invention as it can be easily scratched by obstacles encountered during the passage of the pig through the pipeline 30 . By the same token, the flexibility of layer 51 , which is mainly due to the selected thickness thereof, permits the return back to the relaxed position while the scratches on the surface of the layer 51 remain recorded ready to be interpreted upon passage of the pig through the examined section of the pipeline 30 .
The desired thickness of the layer 51 is easy to determine, for instance by a simple trial-and-error method. As an example, it has been established that in, case of the above example of a diameter of the detector being about 8″, the preferred thickness of the polyurethane disc 50 is about ¾″ and the thickness of the lead layer 51 meeting the above resiliency conditions is about {fraction (1/16)}″. These figures, of course, are optional.
While, at the present time, lead has provided best results in resiliency and retaining the scratch marks on the face of the detector 46 , those skilled in the art will appreciate that other materials can be used to substitute the lead layer 51 . A vast number of different materials including paints applied to the leading face of the disc 50 would also provide satisfactory results both from the standpoint of flexibility and retaining the scratches made during the passage through a the pipeline 30 .
Turning now back to FIG. 3, the rear end portion of the body 32 carries a compression spring 52 . The front end of the spring 52 presses against the rear surface of the flange 45 , while the rear end of the spring 52 engages the surface of the holder plate 35 . The rear guide ring 31 a may be provided with passages (not shown) for the fluid to flow through the pipeline 30 and generate the required propelling force at the front ring 31 .
The spring 52 holds the slider 44 in a relaxed position shown in FIG. 3 . When an obstacle is encountered, the detector 46 deflects and at the same time exerts axial force upon the slider 44 displacing it to the left of FIG. 3, thus triggering the not shown switch mechanism provided within the cavity 43 .
It is advantageous to provide the detector 46 as an easily exchangeable replacement part for the pig. One embodiment of such spare or replacement detector 46 is shown in FIG. 4 . The disc-shaped detector 46 has an outer circumference 56 having a predetermined diameter, for instance 8 ″, as discussed above. The inner central opening 57 a in a sleeve 57 bonded to the disc 50 is compatible with the outer surface of the slider 44 and, in the exemplary size discussed above is about 2″.
An alternative embodiment of the detector 46 is shown in FIG. 6 . Here the detector is again a laminate of a resilient disc 50 with a scratch recording lead face 51 . The laminate is held between opposed flanges 48 , 49 by a series of bolts and nuts 48 a , 49 a . FIG. 5 shows that the assembly of FIG. 6 is again retained on the body 32 between the shoulder portion 45 and the retainer clip 47 .
The detector laminate 50 , 51 shown was produced by first preparing a lead plate having the above thickness of about {fraction (1/16)}″ and major and minor diameters of about 8″ and 2″, respectively. The surface facing the resilient disc 50 was cleaned and roughened. The lead plate was then placed in a compatible form and the desired volume of polyurethane poured, into the form over the lead plate. With the polyurethane cured, sufficient bond was obtained between the polyurethane disc and the lead layer.
Embodiments of the present invention have also been produced, where the detector was simply bonded to the slider 44 thus eliminating the need for the shoulder 45 — clip 47 arrangement. A vast number of other obvious, notoriously known methods of mechanical securement of the detector to the body exist and can be used to secure the detector 46 in operative position.
While the embodiments described above have worked satisfactorily, it was realized that a further improvement may be provided which would not only detect an anomaly but also its general position relative to the periphery of the pipeline.
FIGS. 7 and 8 show such additional improvement
As is the embodiment of FIG. 3, the improved pig comprises a pair of front and rear resilient guide rings 60 , 61 . The front ring 60 is secured to a tubular body 62 having an axis L of elongation, by way of a front end cap 63 threadably engaging a threaded portion 64 projecting from a plug 65 which is fixedly secured, by welding or adhesively, to the inside of the tubular body 62 at the front end thereof. The front end cap 63 holds the front ring 60 between an inner front flange 66 and an outer front flange 67 . The inner front flange 66 is fixedly secured to the front end of the tubular body 62 . Thus, the outer front flange 67 , the front ring 60 and the cap 63 are all fixedly secured relative to the tubular body 62 .
Similarly, the ring 61 is secured to the tubular body 62 by way of a rear end cap 68 threadably engaging a threaded portion 69 projecting from a rear plug 70 which is fixedly secured, by welding or adhesively, to the inside of the tubular body 62 at the rear end thereof. The rear end cap 68 holds the rear ring 61 between an inner rear flange 71 and an outer rear flange 72 . The inner rear flange 71 is fixedly secured to the rear end of the tubular body 62 . The outer rear flange 72 , the rear ring 61 and the cap 68 are thus all fixedly secured relative to the tubular body 62 .
A tubular mandrel 73 is mounted for a free rotation on the body 62 . The mandrel 73 rotates on bushings 74 , 75 . The bushings also prevent axial displacement of the mandrel 73 relative to the body 62 . The mandrel 73 is also freely rotatable relative to the inner front flange 66 and the inner rear flange 71 and their associated assemblies of the front and rear rings 60 , 61 .
Welded to the lower exterior of the mandrel 73 is a tubular member 76 with screwed sealed cap 77 . The tubular member 76 has two functions: it houses a recording system and at the same time provides ballast which maintains the freely rotatable mandrel 73 in a position shown in FIG. 7, regardless of the actual instant position of the discs 60 , 61 and the tubular body 62 fixedly secured to them. The weight of the tubular member 76 will thus maintain the member at a downward, essentially 6o'clock position when viewed axially relative to the mandrel 73 . As a result, all portions of the face of a disk-shaped detector 78 are maintained at all times at a generally constant position with respect to a fictitious vertical reference plane P. See FIG. 8 .
The resilient disc-shaped detector 78 abuts against a plate or shoulder portion 79 which is fixedly secured relative to the mandrel 73 by a weld 80 to the mandrel 73 . The rear surface of the detector 78 abuts a circular plate 81 which, in turn, abuts an annular spacer member 82 . At the opposite end of the spacer member 82 , a plate 83 sealingly encloses the interior of an annular cylindric chamber 83 a disposed between the radially outer surface of the spacer member 82 and an outer annular wall 83 b . The entire chamber 83 a , the spacer member 82 , the rear annular plate 81 , the plate detector 78 and the front annular plate 79 welded to the mandrel 73 are fixedly secured to each other and thus to the mandrel 73 by a series of bolts 84 . The bolts 84 are disposed at a uniform circumferential spacing about the above members and pass through bolt passages 84 a (FIG. 8 ).
The portion of the disc 78 radially outwardly of the plates 79 , 81 is generally referred to as a flexing portion of the detector 78 .
L-shaped springs 86 made of a commercially available spring steel of about {fraction (1/16)}″ have each an axial arm 87 and a radial arm 88 adjoining each other at a coiled central section 89 at an angle, in the embodiment shown, a right angle. The central section 89 has about 3 - 4 coils. The axial arm 88 is provided at its free end with a coiled support section 95 . Both arms are resiliently flexible.
Each spring 86 is pivotable, at the central section 89 , relative to the plate 81 about an associated pivot pin 94 passing through the central section 89 and projecting to both sides thereof. Each pivot pin 94 is held in place by a short, tangential groove 96 (FIG. 9) machined in the face of the annular rear plate 81 turned towards the disc detector 78 . The opposed ends 94 a , 94 b of each pin are pressed against the resilient surface of the detector 78 and are thus held in place. In other words, each spring can swing within a respective plane defined by the L-shape, i.e. a plane parallel with (in the embodiment shown, generally coincident with) the axis-L of the mandrel 73 . The springs 86 are evenly circumferentially spaced with respect to the disc 78 as best seen in FIG. 8 . It will be appreciated that the coincident arrangement with axis-L is not absolutely necessary even though it is preferred.
Each axial arm 87 is provided at its free end with a permanent magnet 90 held in place by the respective support section 95 . Assigned to each magnet 90 is a magnetic position switch 91 . In the embodiment of FIGS. 7 and 8, a magnetic position switch commercially available under the trade name Hamlin has been proposed. As is known, the magnetic, position switch 91 is located in a non-magnetic envelope fixedly secured to the surface of the annular spacer 82 . The non-magnetic envelope can be made from a number of suitable materials for instance from stainless steel, aluminum or a thermoplastic material. In many applications, the magnetic sensors are grouped depending on the accuracy of indication of the pipeline anomaly required.
FIGS. 8 and 9 show that the radial arms 88 of springs 86 are evenly spaced around the detector 78 . The radial arms 88 are each located in an associated groove 92 milled into the face of the disc 78 . The grooves 92 terminate short of the edge of the disc 78 . The remaining portion from the radially outer end of grove 92 to the edge on disc 78 contains a radial hole 97 (FIG. 9 ). Free end portions 93 of the radial arms 88 of the springs 86 are each inserted into a respective hole 97 . The holes co-operate with the pivots 94 to keep the radial arms 88 of springs 86 secured to and generally flush with the surface of the disk 78 at all times.
FIG. 8 further shows that, in the embodiment described, the grooves 92 or the free end portions 93 divide the entire circumference of the disc 78 into twelve segments. They have each a predetermined arc and length of its chord. In the embodiment of FIG. 8, the arc and thus the length of the chord is the same in each segment.
While this arrangement is preferred in most applications, it can be modified to two or more different arcs of the segments.
There are twelve switches disposed about the periphery at slightly counter-clockwise offset locations in which the XII o'clock point is offset counterclockwise by 15 ° so that the uppermost point of the circle is between the XII o'clock and I o'clock position.
If it is desired to find out only whether a particular obstacle is in the upper or lower part of the pipeline, then only two groups of the signal developing switches are required of the usual twelve switches. In case of twelve switches disposed about the periphery of plate 81 and offset as described, a group of switches at the offset X, XI, XII, I, II and III o'clock positions would serve in determining an anomaly in the upper part of the pipeline, while switches in the IV, V, VI, VII, VIII and IX o'clock position would transmit a signal corresponding to the anomaly in the lower part of the pipeline. If a more detailed indication is required, more groups, each having a fewer number of switches, would be grouped or each switch would indicate anomaly at its position about the circumference of the pipeline. Customers normally specify their requirements concerning the accuracy required.
In operation, the pig is propelled through an associated pipeline in a fashion as already described. When an obstacle is encountered, a segment of the disc 78 becomes deflected in the direction D shown at the bottom of FIG. 7 . Assuming that the detected obstruction is at the lower part of the pipeline, the radial arms 88 follow the local deflection of the disc raising the axial arms 87 of the lower springs 86 at the offset 6 and 7 o'clock positions to bring the associated magnets 90 into contact with the magnetic sensor switches 91 . The sensing switches 91 then transmit electric signal to a conventional electronic recording device located within the tubular member 76 . This is effected by leads, not shown; passing through passages 98 in the disks 81 , 78 and 79 .
The springs 86 , holding each a magnet and the annular spacer 82 holding a plurality of magnetic switches 91 can also be generally referred to as transmission devices comprised of a first transmission member and a second transmission member. In the embodiment described the spring 86 functions as the first transmission member. The spacer 82 of the embodiment described is an example of a second transmission member. It will be understood that the particular embodiment described is not the only one readily conceivable and that the functions can be easily reversed. The designation of the transmission members as first and second is therefore to be understood as a general definition of the two and does not necessarily refer to which of the members carries the magnet 90 and which carries the switch 91 . For the same reason, the term “first support portion” of the embodiment shown is designated as the one carrying permanent magnet while the “second support portion” of the second transmission member carries the switch, it being understood that this function can readily be reversed. Therefore the above general terms must be interpreted in their general meaning and not to be limited to their meaning with respect to the embodiment disclosed. The sensing switches, their leads (not shown) passing through one or more passages 98 to the recording device in the tubular member 76 and the recording device itself do not form, a part of the present invention and are therefore not described in detail. They are comprised of commercially available components.
FIG. 11 shows an improvement of the embodiment of FIG. 7 . The improved embodiment presents a substantially simpler and thus less expensive structure and an improved reliability in operation.
The front and rear carrying guide rings 60 , 61 , the mandrel 73 rotatable on the elongated body or carrier 62 , and the tubular member 76 secured to the lower portion of the mandrel 73 , are identical in structure and function with the embodiment of FIG. 7 and are therefore referred to with the same reference numbers.
In FIG. 11, the resilient, disc-shaped detector body 178 has a different, substantially simplified structure. The detector is provided with two coaxially arranged, resiliently flexible discs 179 , 180 , each having a resiliently flexible outer portion and, preferably, with an intermediate scratch indicating layer 181 . The disc 179 presents an embodiment of what is referred to as “a first member,” the disc 180 as “a second member” or vice-versa. In the embodiment shown the layer 181 is a thin sheet of plastic material cut into a disc-like configuration having the same diameter as the rear or trailing disc 180 , as viewed from the standpoint of direction D in which the pig advances through the pipeline. The diameter of the trailing disc 180 is, preferably, but not necessarily, larger than that of the leading disc 179 . The layer 181 is sandwiched between the leading disc 179 and the trailing disc 180 .
The assembly of discs 179 , 180 , 181 is fixedly secured to the mandrel 73 by a pair of opposed flanges 182 , 183 presenting and embodiment of what! can generally be referred to as “a support of a securement portion.” The flanges are welded or otherwise fixedly secured to the mandrel 73 , generally as in the previously described embodiment. The bolts 184 , disposed at a uniform circumferential spacing, secure the discs much in the same fashion as in the previously described embodiment.
Thus, the assembly of discs 179 , 180 and 181 is freely rotatable about the axis L by virtue of its securement to the freely rotatable mandrel 73 . Viewed from the standpoint of direction D, each disc 179 , 180 , has a leading face and a trailing face.
Embedded in the leading disc 179 near its trailing face 185 is a series of equidistantly circumferentially spaced apart permanent magnets 186 . Similarly, there are embedded in the trailing disc 180 near its leading face 187 , equidistantly circumferentially spaced apart magnetic switches or sensors 188 which are aligned each with one of the magnets 186 . Each pair of the magnet 186 and sensor 188 presents an embodiment of an electronic signal generating means, wherein the magnet and the sensor forms a first and a second electronic signal generating element or vice-versa.
The switches or sensors 188 co-operate with the, magnets 186 in a fashion similar to that of the previously described embodiment of FIG. 7 . That is to say, when a respective magnet 186 is at a close proximity to its associated sensor 188 , the sensor 188 is activated to emit a first signal communicated by the respective lead 189 to a conventional recording device located in the tubular member 76 . The close proximity between the magnets and the sensors 188 exists when the two discs 179 , 180 are in a relaxed state shown in FIG. 11 .
As shown in FIGS. 12-14, when an obstruction is encountered, as the body 62 advances in the direction D, the close proximity of one or more of the sensors 188 with their associated magnets 186 is disturbed causing a change in the electronic signal. The sensors 188 , the magnets 186 and the recording device located in the tubular member 76 are all commercially available items. Their particular design does not form a part of the present invention and therefore is not described in detail.
Turning now to FIG. 12, a situation is depicted where a relatively small obstruction 190 has been encountered by the pig traveling in the direction D. At a position shown, the obstruction 190 protrudes into the inside of the pipeline at a radius (measured from the axis L) which is larger than the radius of the leading disc 179 but smaller than that of the trailing disc 180 . Therefore, the leading disc 179 passes by the obstruction 190 maintaining its relaxed state. As a flexing part of the trailing disc 180 encounters the obstruction 190 , it is subjected to an axial force directed opposite to the direction D. The opposite force is also referred to as “a force in a predetermined axial direction.” The flexing part of the trailing disc 180 flexes rearwards as shown in the drawing. This flexing causes disturbance of the relationship between the respective pair comprised of the magnet 186 and the associate sensor 188 . As a result, a second electronic signal, different from the first signal, is communicated to the recording device in tube 76 . The position of the disturbed arrangement is also recorded since the ballast, formed by or secured to the tube 76 maintains a position of the tube 76 , vertically aligned with the axis L.
In FIG. 13 a larger abnormality 190 has been encountered which reaches into the pipeline at a radius smaller than either of the two discs 179 , 180 . At the outset, both discs flex rearwards as shown. The magnet or magnets 186 remain at a close spacing from the associated sensor 188 . However, as shown in FIG. 14, as soon as the leading disc 179 passes the obstruction, it springs forwards to a relaxed state while the trailing disc 180 remains flexed thus disturbing the close arrangement between the magnet 186 and the associated sensor 188 again resulting in a change of the electronic signal.
The presence and radial position of the abnormality 190 can be double checked upon eventual examination of the scratches caused by the abnormality 190 on the leading surface of the scratch disc 181 which, preferably, is a thin, separate disc from plastic polyethylene. In an exemplary embodiment suitable for a pipeline having a 20 ″ ID, the outside diameter of the large, (in the embodiment shown, trailing) disc 180 would be about 19½″ and that of the small diameter, leading disc 179 would be about 19″. The thickness of each disc is about {fraction (3/4 )}″. The discs 179 , 180 are preferably integrally formed but an embodiment wherein they would be subdivided into a plurality of independently flexing segments with aligned pairs of signal generating devices may also be feasible under certain circumstances.
Those skilled in the art will readily appreciate that many equivalent arrangements to those described may exist. For instance, the disposition of the magnets 186 and the sensors 188 can be reversed and does not even have to be uniform but may alternate within one of the two discs with an appropriate modification of the other disc. While it is preferred that the trailing disc 180 have a diameter larger than that of the leading disc, the arrangement is optional. The two discs may also have generally the same diameter. In an extreme, not recommended, the disc 179 could even have a larger diameter than of the trailing disc 180 .
The flexing portion described is a disc. However, an equivalent arrangement could be made in an embodiment where the disc would be replaced by a plate or a strip where the checkup of a generally planar surface is required. Even in a pipeline monitoring arrangement, a system of several independent strips, each having a leading flexing portion and a trailing flexing portion, could be used, while, obviously, the disc-shaped arrangement is preferred for its simplicity.
Those skilled in the art are aware that other equivalent systems producing electronic signal suitable for use in the mechanism of the present invention are commercially available.
Accordingly, many different modifications of the overall arrangement of the monitoring pig of the kind disclosed can be made which may depart from the embodiments described without departing from the gist of the present invention. | An obstacle detecting pig for preliminary inspection of a section of a pipeline travels through the section and determines if there are any restrictions that exceed industry guidelines or that might damage other pigs that require the full bore of the pipe. In a first embodiment, a disk-shaped segmented resilient member ( 14 ) is mounted in the body of the pig. Its outside diameter is smaller by a spacing ( 21 ) than the inside diameter of the pipeline ( 15 ). The spacing is set at the maximum tolerable size of the obstacle encountered. The deformation of the member ( 14 ) is transmitted by a linkage ( 22 ) to a slider ( 16 ) activating a switch system signaling that an obstacle has been encountered. A non-resiliently deformable checkup disk ( 19 ) may be provided at the rear end of the pig, to double check that a no-signal passage through the pipe is not due to failure of the switching system. In a particularly preferred embodiment, the resilient member is a disc-shaped detector ( 46 ) made from an elastomer and provided at its leading surface with a scratch recording layer ( 51 ), for instance a layer of lead which is thin enough to follow resilient deformations of the elastomeric ring ( 50 ) as it encounters an obstacle, and return of the ring back to its regular, shape. The scratches caused on the recording layer are evaluated after the passage of the pig through the examined pipeline section. The detector is mounted directly on a slider ( 44 ) or the like operating device designed to produce electric signal when an anomaly is encountered. Preferably, the detector ( 46 ) is a replaceable element of the pig. In another embodiment described and claimed, the detector is comprised of a pair of flexible discs having embedded therein pairs of electronic signal providing means such as a magnet and a magnetic switch or sensor.
The device is structurally simple thus providing low manufacturing and operation costs and simple operation. | 5 |
RELATED APPLICATIONS
This application is a Continuation of application Ser. No. 07/912,344, filed Jul. 13, 1992, now abandoned; which is a Continuation of application Ser. No. 07/283,561, filed Jul. 15, 1988, now abandoned; which is a Division of application Ser. No. 06/792,372, filed Oct. 29, 1985, now U.S. Pat. No. 4,822,776; which is a Division of application Ser. No. 06/414,098, filed Sep. 7, 1982 (now U.S. Pat. No. 4.603,106); which is a Continuation-in-Part of application Ser. No. 06/351,290, filed Feb. 22, 1982, now abandoned; which is a Continuation-in-Part of application Ser. No. 06/299,932, filed Sep. 8, 1981, now abandoned; to which Applicants claim the benefit of the filing date under 35 U.S.C. § 120.).
RELATED PUBLICATIONS
The applicants are authors or coauthors of two articles directed to the subject matter of the instant invention: (1) [applicants only] “Studies of Endotoxin-Induced Decrease in Lipoprotein Lipase Activity”, J. EXP. MED. 154 at 631-639 (September, 1981, published after Sep. 8, 1981), incorporated herein by reference; and (2) [co-authors with Phillip H. Pekala and M. Daniel Lane]: “Lipoprotein Lipase Suppression in 3T3-L1 Cells by an Endotoxin-Induced Mediator from Exudate Cells”, PROC. NAT'L. ACAD. SCI. 79 at 912-916 (February, 1982, published after Feb. 22, 1982), also incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed generally to methods and associated materials for analysis of the effect and operation of invasive stimuli upon animal hosts, and in particular, is concerned with the mechanism and magnitude of the effect that such invasive stimuli may exert upon the activity of anabolic enzymes present in the host.
2. Description of the Prior Art
Several common physiological and biochemical derangement have been seen in various mammalian hosts responding to variety of invasive stimuli such as bacterial, viral and protozoan infections, as well as tumors and endotoxemia. For example, these responses include fever, leukocytosis, hyperlipidemia, reduced food intake and activity, and other modifications in muscle, white blood cell and liver metabolism. Recently, a hypertriglyceridemia in rabbits infected with a protozoan parasite, Trypanosoma brucei was reported by C. A. Rouser and A. Cerami, MOL. BIOCHEM. PARASITOL. 1 at 31-38 (1980). The reported hypertriglyceridemia was accompanied by a marked decrease in the activity of the enzyme lipoprotein lipase (LPL) in peripheral tissues.
LPL activity has been observed by others, and it has been noted that this condition has existed when the human bodywas in shock. See E. B. Man, et al, “The Lipids of Serum and Liver in Patients with Hepatic Diseases”, J. CLIN. INVEST. 24 at 623, et seq. (1945); See also John I. Gallin, et al, “Serum Lipids in Infection”, N.ENGL. J. MED. 281 at 1081-1086 (Nov. 13, 1969); D. Farstchi, et al., “Effects of Three Bacterial Infections on Serum Lipids of Rabbits”, J. BACTERIOL. 95 at 1615, et seq. (1968) S. E. Grossberg, et al., “Hyperlipaemia Following Viral Infection in the Chicken Embryo: A New Syndrome”, NATURE (London) 208 at 954, et seq. (1965); Robert L. Hirsch, et al., “Hyperlipidemia, Fatty Liver and Bromsulfophthalein Retention in Rabbits Injected Intravenously with Bacterial Endotoxin”, J. LIPID. RES. 5 at 563-568 (1964); and Osamu Sakaguchi, et al., “Alterations of Lipid Metabolism in Mice Injected with Endotoxins”, MICROBIOL. IMMUNOL. 23 (2) at 71-85 (1979); R. F. Kampschmidt, “The Activity of Partially Purified Leukocytic Endogeneous Meliator in Endotoxin-Resistant C3H/HeJ Mice”, J. LAB. CLIN. MED. 95 at 616, et seq. (1980); and Ralph F. Kampschmidt, “Leukocytic Endogeneous Mediator”, J. RET. SOC. 23 (4) at 287-297 (1978).
While the existence of “mediators” was at least suspected, the effect, if any, that they had on general anabolic activity of energy storage cells was not known. The presentapplicants suspected that these “mediators” exerted a depressive effect upon the activity of certain anabolic enzymes, whose reduced activity was observed in instances where the host entered the condition of shock in response to invasion. Thus, the relationship of the mediator produced by endotoxin-stimulated peritoneal mouse exudate cells, upon endotoxin-sensitive and endotoxin insensitive mice alike, and the development through this investigation, of a reagent for measuring anabolic enzyme activity, was set forth in Ser. No. 299,932, and the further investigation of this system in conjunction with the 3T3 L1 “preadipocyte” model system, and the corresponding development of methods and associated materials for developing antibodies to the “mediators” as well as screening procedures for the identification and development of drugs capable of controlling the activity of these “mediators” was set forth in application Ser. No. 351,290. The work done to date indicates that a need exists for methodology andassociated diagnostic materials, to enable further investigationof the “mediator” phenomenon to proceed, as well as to provide practical diagnostic tools useful in the treatment of the adversesequclae of infection and concomitant shock.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, a method for preparing a mediator substance for use in assessing the state of anabolic enzymes in mammals, is disclosed, whichfinds particular utility in the instance where the mammals areundergoing invasive stimuli such as, viral agents, bacteria, protozoa, tumors, endotoxemia and others. In its simplest aspect, the method comprises gathering a sample of macrophage cells from amammal and incubating a portion of the macrophage cells with astimulator material associated with an invasive event. Forexample, the stimulator material may be endotoxin, in the instanceof endotoxemia, trypanosomes, in the instance of the above mentioned protozoan parasite Trypanosoma brucei , and others.
While the peritoneal exudate cells illustrated in our present and previous applications exemplify sources for themacrophage cells, it is to be understood that such cells may begathered from other than the peritoneal area, and that the present invention contemplates such variation within its scope.
The macrophage cells and the stimulator material are incubated as indicated, and thereafter, the macrophage cells areinduced to produce a mediator substance capable of supressing theactivity of the anabolic enzymes. Preferably, the inducement ofmediator production is accomplished during the incubation periodwhich may, for example, extend up to about 20 hours. The resulting medium may be appropriately treated to recover the mediator substance, and, for example, may be centrifuged, and the supernatant containing the mediator substance drawn off, or the mediator may be precipitated with a 40-60% solution of ammonium sulfate
As mentioned earlier, the mediator substance has a broad range of effects, including inhibitive effects that have beenobserved with respect to anabolic enzymes such as lipoproteinlipase (LPL), acetyl Coenzyme A carboxylase, fatty acid synthetase and the like. Also inhibitive effects have been found with red blood cell formation, as the mediator substance has been found tobe capable of inhibiting the growth and differentiation of erythroid committed cells, by the suppression of a number of growth and differentiation inducers, such as dimethylsulfoxide (DMSO),hexamethylene bisacetamide, butyric acid, hypoxanthine and thelike, as illustrated later on herein in specific examples.
A further embodiment of the present invention comprises a method for detecting various invasive stimuli by their capability of inhibiting the activity of one or more anabolic enzymes. In this method, a plurality of macrophage cell samples, may beprepared and selectively inoculated with a number of known stimulator materials, each characteristic in its effect upon differing anabolic factors. One of the macrophage samples may be inoculated with material from the presumed situs of the infective stimulus, and all samples may thereafter be incubated in accordance with the method described above. Thereafter, testing of each of the supernatants with the mediator substances derived fromthe known stimulator materials, would provide a comparativecontinuum for the identification of any invasive stimulus foundpresent. This testing method may utilize the 3T3 L1 cell system, for example, in the instance where lipoprotein lipase (LPL)activity is utilized as a parameter. Likewise, in the instancewhere red cell inducers are utilized, the Friend virus-transformed erythroleukemia cells may be inoculated and thereafter observed.See Friend, C., Sher, W. Holland J. G. and Sato, G. PROC. NATL.ACAD. SCI. 68, at 378-382; Marks, P. A., Rifkind, R. A., Terada, M., Ruben, R. C., Gazitt, Y. and Fibach, E. in ICN-UCLA Symposia on Molecular and Cellular Biology, Vol. X. “Hematopoietic Cell Differentiation”. Ed. by D. W. Golde, M. J. Kline, D. Metcalf and C. F. Fox (Academi Press, New York), pp. 25-35 (1978). Naturally, other cellular systems may be utilized in the instance wherespecific activities may be appropriately observed, and the invention is not limited to the specific cellular systems set forth herein.
The invention includes methods for detecting the presence of samples of the various invasive stimuli in mammals by measuring mediator substance activity in the mammals. Thus, a number of mediatorsubstances may be prepared from the incubation of individual cell samples with known stimulator materials, and these mediator samples may thereafter be used to raise antibodies capable of specifically detecting the presence of the respective mediator substance. These antibodies may be prepared by known techniques, includingthe well known hybridoma technique for example, with fused mousespleen lymphocytes and myeloma, or by development in various animals such as rabbits, goats and other mammals. The known mediator samples and their antibodies may be appropriately labelled and utilized to test for the presence of the mediator substance in, for example, serum, as one may measure the degree of infection, and determine whether infection is increasing or abating, by observing the activity of the mediator substance therein. A variety of well known immunological techniques may be utilized in accordance with this aspect of the present invention, including single and double antibody techniques, utilizing detectible labels associated with either the known mediator substances, or their respective associated antibodies.
A further embodiment of the present invention relates to a method for preventing the occurrence of shock in mammals,comprising detecting the presence and shock promoting activity ofa mediator substance in the mammal, and thereafter administeringan antibody to the mediator substance, in an amount effective toprevent the development of shock in the mammal.
The invention particularly relates to a method of treating shock in humans, comprising administering to a human a shock-reducing amount of an antibody specific to a mediator substance.
Also, an assay system is disclosed and may be prepared for the screening of drugs potentially effective to inhibit thesynthesis or activity of the mediator substance. In the former instance, the effect of the test drug on the production of mediator by stimulated macrophages is determined, In the latter instance,a mediator substance may be introduced to cellular test systems, such as the 3T3 L1 cells, and the prospective drug may then be introduced to the resulting cell culture and the culture thereafter examined to observe any changes in mediator activity, either fromthe addition of the prospective drug alone, or the effect ofadded quantities of the known mediator substance.
A number of materials, compounds and agents have already been tested to determine their effect if any on mediator substanceproduction and activity. As discussed in further detail in thedescription, infra., only the steroid dexamethasone exhibited any inhibitory effect, and that effect appeared to be limited to theproduction of the mediator substance. Further agents, drugs, etc. can however be tested in the manner such as that employed withdexamethasone, and described herein.
The preparation of the mediator substance, and the determination of the importance of its activity, has resulted in the development of numerous avenues of diagnostic and therapeutic application. It is clear from the foregoing and following, thatthe detection of invasive stimuli may be made by the identification of the mediator substance, either directly or through the development of antibodies useful in immunological diagnosis.Further, these same antibodies may be utilized for direct treatment by control of mediator activity, to avert the development of shock in mammals, while the mediator substance may be utilized as screening agents in an assay system for the identification ofdrugs, agents and other substance (capable of neutralizing theadverse effects of the mediator substance, and thereby providing treatment of the adverse sequelae of infection.
Accordingly, it is a principal object of the present invention to provide a method for the preparation of a mediator substance exhibiting suppressive effects upon anabolic enzyme activity in mammals.
It is a further object of the present invention to provide a method for detecting the presence of a mediator substance in mammals in which invasive stimuli such as infection are suspected to be present.
It is a further object of the present invention to provide a method and associated assay system, for screening substance such as drugs, agents and the like, potentially effective incombating the adverse effects of the mediator substances in mammals.
It is a yet further object of the present invention to provide a method for the treatment of mammals to control the activity of said mediator substance so as to mitigate or avert the adverse consequences of their activity.
Other objects and advantages will become apparent to those skilled in the art from a review of the ensuing description,which proceeds with reference to the following illustrativedrawings
DESCRIPTION OF THE DRAWINGS
FIG. 1A shows the effect of serum from endotoxin-sensitive mice treated with endotoxin on adipose tissue LPL activity in endotoxin-sensitive mice. Mediator activity was observed and conclusions drawn as set forth in Example, paragraph E herein. The data are expressed as the mean (+SEM) of six animals for each group.
FIG. 1B shows the effect of serum from endotoxin-sensitive mice treated with endotoxin on adipose tissue LPL activity in endotoxin-resistant mice. The data are expressed asthe mean (±SEM) of three animals for each group.
FIG. 2 shows the effect of medium from exudate cell cultures on adipose tissue LPL in endotoxin-resistant mice. The data are presented as the mean (±SEM) of four-or five animals.
FIG. 3 shows the effect of conditioned medium from endotoxin-treated mouse peritoneal exudate cells over lipoproteinlipase activity of 3T3-L1 cells. Data are expressed as mean SEM (n=4).
FIG. 4 shows the effect of conditioned medium from endotoxin-treated mouse peritoneal exudate cells on the activitiesof acetyl CoA carboxylase and fatty acid synthetase in 3T3-L1 cells. Three hundred (300) μl of conditioned medium was added to cultures of 3T3-L1 cells (4.2×10 6 cells/dish) in 6 cm dishes containing 3.5 ml of DMIE medium and 10% fetal calf serum. After the indicated times of incubation, the enzymatic activity of acetyl CoA carboxylase (identified by the symbol “•”) and fatty acid synthetase (identified by the symbol “∘”) on a digitonin releaseable cytosolic fraction of the cells was assessed.
FIGS. 5A and 5B show the effect of mediator that suppresses the synthesis of acetyl CoA-carboxylase. At the indicated times after exposure of the 3T3-L1 cells to the mediator (300 μl of conditioned medium, the cells were pulse-labeled with 0.5 mCi of 35 S-methionine for 1 hour. Cytosolic fractions were obtained by digitonin treatment of a monolayer. Aliquots of the cytosolicfractions (2×10 5 cpm for all determinations) were incubated with anti-acetyl CoA carboxylase and the immunoprecipitable material isolated and characterized as described in Example II, infra.Panel A: Autoradiogram of a 7.5%-acrylamide-0.1% SDS gel analysis of immunoadsorbable protein. Lane 1—control, without exposure to mediator; Lanes 2, 3, and 4—exposure of the cells to the mediator for 3, 6 and 20 hours, respectively. Panel B: Results of a densitometric scan of the autoradiogram, indicating percentof immunoadsorbable material remaining relative to control, afterexposure to the mediator.
FIGS. 6A and 6B show the effect of a mediator that suppresses the synthesis of fatty acid synthetase. Experimental design isidentical to that described in the legend to FIG. 5 . Panel A:Autoradiogram of a 7.5%-acrylamide-SDS gel analysis of immunoadsorbable fatty acid synthetase. Lane 1—control, without exposure to mediator; Lanes 2, 3, and 4, exposure of the cells to the mediator for 3, 6 and 20 hours, respectively. Panel B: Results of a densitometric scan of the autoradiogram, indicating percent of immunoadsorbable material remaining relative to control after exposure to the mediator.
FIG. 7 shows the effect of the mediator on 35 S-methionine incorporation into protein. 3T3-L1 cells were incubated with 300 μl of conditioned medium from endotoxin-treated mouse peritoneal exudate cells for the appropriate period and proteinpulse-labeled with 0.5 mCi of 35 S-methionine for 1 hour. Soluble proteins were obtained by digitonin treatment of the cells, theremainder of the monolayer was extracted with NP-40 and a membrane protein fraction obtained. Incorporation of 35 S-methionine into acid precipitable material was determined as described in ExampleII, infra. The incorporation of radioactivity into soluble protein (•) or membrane protein (∘) following exposure of the cells to the mediator are shown for the indicated time.
FIG. 8 shows the effect of mediator on protein synthesis in the cytosolic fraction of the cells. Autoradiogram of a 7.5%-acrylamide-0.1% SDS gel analysis of 35S-methionine labeled cytosolic protein after exposure of the cells to the mediator.3T3-L1 cells were pulse labeled and the soluble protein was obtained by digitonin as described in Example II. Aliquots (2×10 5 cpm) of the cytosolic fraction for each time point were applied tothe gel and electrophoresed. Lanes 1 and 2, control without exposure to mediator; Lanes 3 and 4, 1 hour exposure to the mediator; Lanes 5 and 6, 3 hours of exposure; Lanes 7 and 8, 6 hours of exposure; Lanes 9 and 10, 20 hours of exposure to conditioned medium from mouse peritoneal exudate cells not exposed to endotoxin; Lanes 11 and 12, exposure of cells to mediator for 20 hours
FIG. 9 shows the effect of mediator on protein synthesis in the membrane fraction of the cells. Autoradiogram of a 7.5%-acrylamide-0.1% SDS gel analysis of 35 S-methionine labeled membrane protein after exposure of the cells to the mediator.Experimental design was identical to that described in the legendto FIG. 8 . Membrane proteins were obtained by NP-40 extraction as described in Example II. Lanes 1 and 2—control, without exposure to mediator; Lanes 3 and 4, 1 hour of exposure to the mediator; Lanes 5 and 6, 3 hours of exposure; Lanes 7 and 8, 6 hours of exposure; Lanes 9 and 10, 20 hours of exposure of the cells to conditioned medium from mouse peritoneal exudate cellsnot exposed to endotoxin; Lanes 11 and 12, exposure to mediator for 20 hours.
FIGS. 10A and 10B show the effect of conditioned media from mouse macrophage cultures on the cell growth and heme content inFriend cells.
Friend cells (clone DS-19) were incubated for 96 hours in the absence or in the presence of Me 2 SO (1.5 vol %). Conditioned media (80 μl/ml of growth medium) from mouse peritoneal macrophage cultures stimulated or not stimulated with endotoxin(5 μg/ml) were added at the beginning of culture. Cell members were counted with a Cytograf model 6300 and expressed as per cent inhibition of the control cells. Cell number in untreated controlculture was 3×10 6 cells/ml. Heme content was determined fluorometrically as described previously (Sassa, S., Granick, S., Chang, C. and Kappas, A. (1975) In Erythropoiesis, ed. by K.Nakao, J. W. Fisher and F. Takaku (University of Tokyo Press, Tokyo) pp. 383-396). Data are the mean of duplicate determinations. The number of trypan blue positive cells assessed by Cytograf counting was8-10% for all cultures.
FIGS. 11A and 11B show the dose dependent effect of the endotoxin-stimulated macrophage mediator on cell growth and erythroid differentiation of Me 2 SO-treated Friend cells. Cells were incubated for 96 hours in the presence of 1.5% Me 2 SO with increasing concentrations of the macrophage mediator. Assays of enzymes andintermediates were performed as described in Example III, infra.Data are the mean of duplicate determinations.
FIG. 12 shows the effect of delayed addition of the endotoxin-stimulated macrophage mediator on cell growth anderythroid differentiation.
Friend cells were incubated for 96 hours without changing the medium. Me 2 SO was added at time 0 to a final concentration of 1.5 vol %, while the endotoxin-stimulated macrophage mediator was added at the times indicated on theabscissa (80 μl conditioned medium per ml of growth medium). Cell number, activities of ALA dehydratase and PBG deaminase, hemeand protoporphyrin contents were assayed at the end of incubationas described in Example III, infra. Data are the mean of duplicatedeterminations.
Values for control cultures treated with Me SO alone were as follows:
Cell number
3.0 (×10 −6 /ml)
ALA dehydratase
3.00 (nmol PBG/10 6 cells, h)
PBG deaminase
120 (pmol uroporphyrinogen/10 6
cells, h)
Protoporphyrin
0.57 (pmol/10 6 cells)
Heme
520 (pmol/10 6 cells)
FIGS. 13A and 13B show the effect of the endotoxin-stimulated macrophage mediator on cell growth and heme content in Friendcells treated with HMBA, butyric acid, hypoxanthine or hemin.
Cells were incubated for 96 hours without changing the medium; inducing chemicals and the endotoxin-stimulated macrophage mediator (80 1 added/ml of growth medium) time 0. Final concentrations of chemicals were mM for HMBA, 1.3 mM for butyric acid, bmM for hypoxanthine and 0.1 mM for hemin. Assays were performed as described in Example III, infra. Data are the mean of duplicate determinations.
FIGS. 14A and 14B show the effect of endotoxin-stimulated macrophage mediator on the growth and differentiation of Friend cells growing at a constant rate.
DETAILED DESCRIPTION
As disclosed in our above referenced co-pending applications on this subject matter, we have discovered an agent which we identify herein as a mediator substance, that is produced bymammalian cells in response to stimulation by materials we referto herein as stimulator materials, that characteristically accompany an invasive stimulus, such as bacteria, virus, some tumors, protozoa and other toxins such as endotoxemia. We have observedthat the mediator substance causes the metabolism of certain of the cells of the mammal to switch from an anabolic state to acatabolic state. In particular, the mediator substance appears to suppress the activity of anabolic enzymes, such as lipoproteinlipase (LPL), and the other enzymes and inducing agents listedearlier herein. It is theorized that this mediator substance is part of a communications system in mammals, between the immune system and the energy storage tissues of the body. Thus, inresponse to various invasive stimuli in mammals, such as thoselisted before, it is theorized that the mediator substance is produced and exert an effect on energy storage tissue such asadipose tissue, muscle, the liver,and the like, of the impendingneed for energy to combat the invasion. More particularly, themediator substance may cause these storage tissues to switch from an anabolic to a catabolic state, to facilitate the supplyof such energy. If the invasion is of short duration, themammal can quickly recover and replenish its energy stores; however, if the invasion is of a chronic nature, shock generally manifested by complete energy depletion, cachexia and death, can result.
During the initial work wherein the foregoing observations were made, the method for preparing the mediator was developed, and an illustrative preparation is set forth initially in Example I, in paragraph D, wherein peritoneal exudate cellswere appropriately cultured and thereafter incubated in the presence of the known stimulator material endotoxin. After incubation, the macrophage cells are induced to produce the mediator substance. In one aspect, such inducement can occur over anextended incubation, i.e. on the order of 20 hours or more. The exact period for such incubation, however, may vary, and theinvention is not limited to a specific time period.
Thereafter, the mediator substance may be recovered from the cell culture and stored for later use in one or more of theways disclosed herein. Recovery may be effected by one of numerous well known techniques, including centrifugation and precipitation. For example, the culture described in paragraph D of Example I, was centrifuged and the supernatant thereafter drawnoff. Alternately, the mediator may be precipitated either witha 40-60% solution of ammonium sulfate or by adsorption onto DEAE cellulose or like exchange resins. The choice of the particularmethod for recovery of the mediator substance is within the skillof the art.
The invention also relates to methods for detecting the presence of invasive stimuli in mammalian hosts by measuring thepresence and activity of the mediator substance. As mentioned earlier, the mediator substance can be used to produce antibodies to themselves in rabbits, goats, sheep, chickens or other mammals, by a variety of known techniques, including thehybridoma technique utilizing, for example, fused mouse spleenlymphocytes and myeloma cells. The antibody can be isolated bystandard techniques and utilized as a test for the presence ofthe mediator substance in the suspected mammalian hosts.
Further, the antibody or antibodies can be utilized in another species as though they were antigens, to raise furtherantibodies. Both types of antibodies can be used to determinethe presence of mediator substance activity in the mammalianbody, particularly in human serum, so as to determine the presenceof invasive stimuli such as bacterial, viral, or protozoan infection, or the presence of certain tumors, and to follow the course of the disease. For purposes of the following explanation, theantibody or antibodies to mediator activity, will be referred toas Ab 1 the antibody or antibodies raised in another species will be identified as Ab 2 .
The presence of mediator substance activity(ies) in the serum of patients suspected of harboring toxic levels thereof canbe ascertained by the usual immunological procedures applicable tosuch determinations. A number of useful procedures are known.Three such procedures which are especially useful utilize eithermediator labeled with a detectable label, antibody Ab 1 labeled with a detectable label, or antibody Ab 2 labeled with a detectable label. The procedures may be summarized by the following equations wherein the asterisk indicates that the particle is labeled, and “Med” stands for mediator activity:
A. Med*+Ab 1 =Med*Ab 1
B. Med+Ab 1 *=MedAb 1 *
C. Med+Ab 1 +Ab* 2 =Med Ab 1 Ab 2 *
The procedures and their application are all familiar to those skilled in the art and accordingly may be utilized interchangeably within the scope of the present invention. The “competitive” procedure, Procedure A, is described in U.S. Pat. Nos. 3,654,090 and 3,850,752. Procedure C, the “sandwich” procedure, is described in U.S. Pat. Nos. RE 31,006 and 4,016,043. Still other procedures are known such as the “double antibody”, or “DASP” procedure.
In each instance the mediator substance forms a complex with one or more antibody(ies) and that one member of the complexis labeled with a detectable label. The fact that a complex hasformed and, if desired, the amount thereof, can be determined by known methods applicable to the detection of labels.
It will be seen from the above, that a characteristic property of Ab 2 is that it will react with Ab 1 . This is because Ab 1 raised in one mammalian species has been used in another species as an antigen to raise the antibody Ab 2 . For example, Ab 1 may be raised in rabbits using a mediator as the antigen and Ab 2 may be raised in goats using Ab 1 as an antigen. Ab 2 therefore would be an anti-rabbit antibody raised in goats. For purposes of thisdescription and claims, Ab 1 will be referred to as a mediator activity antibody and Ab 2 will be referred to as an antibody reactive with a mediator activity antibody or, in the alternative, an “anti-antibody”.
The labels most commonly employed for these studies are radioactive elements, enzymes, chemicals which fluoresce whenexposed to ultraviolet light, and others.
A number of fluorescent materials are known and can be utilized as labels. These include, for example fluorescein, rhodamine and auramine. A preferred detecting material is anti-rabbit antibody prepared in goats and conjugated with fluorescein throughan isothiocyanate.
The mediator composition(s) can also be labeled with a radioactive element or with an enzyme. The radioactive label canbe detected by any of the currently available counting procedures. The preferred isotope 14 C, 131 I, 3 H, 125 I and 35 S. The enzyme label can be detected by any of the presently utilized calorimetric spectrophotometric, fluorospectrophotometric or gasometric techniques. The enzyme is conjugated to the selected particle by reaction with bridging molecules such as carbodiimides, diisocyanates, glutaraldehyde and the like. Many enzymes which can be used in these procedures are known and can be utilized. The preferred are peroxidase, β-glucuronidase, β-D-glucosidase, β-D-galactosidase, urease, glucose oxidase plus peroxidase, galactose oxidase plus peroxidase and acid phosphatase. U.S. Pat. Nos. 3,654,090; 3,850,752; 4,016,043; are referred to by way of example for their disclosure of alternate labeling material, and materialsHigh levels of mediator activity in the mammalian bodymay be toxic to the mammal and cause irreversible shock. Theantibody(ies) specific to a mediator is useful to treat hosts suffering from this metabolic derangement. The patient can be treated for example, parenterally, with a shock-reducing, effective doseof the antibody to neutralize at least a portion of the mediator.The dose will, of course, vary in accordance with the factors wellknown and understood by the physician or veterinarian such as age,weight, general health of the patient and the concentration of themediator.
In a further embodiment of this invention, commercial test kits suitable for use by a medical specialist may be prepared to determine the presence or absence of mediator substances in a suspected host. In accordance with the testing techniquesdiscussed above, one class of such kits will contain at least thelabeled mediator or its binding partner, an antibody specificthereto. Another which contain at least Ab 1 together with labeled Ab 2 . Still another will contain at least Ab 1 and directions, of course, depending upon the method selected, e.g., “competitive”, “sandwich”, “DASP” and the like. The kits may also contain peripheral reagents such as buffers, stabilizers, etc.
Accordingly, test kits may be prepared with various components to detect the mediator substance in sera or aqueous media. A first kit may be prepared to comprise:
(a) a predetermined amount of at least one labeled immuno-chemically reactive component obtained by the direct or indirect attachment of a mediator substance or a specific binding partner thereto to a detectable label;
(b) other reagents; and
(c) directions for use of said kit.
More specifically, a diagnostic test kit for the demonstration of a mammal's reaction to invasive stimuli may be prepared comprising (a) a known amount of one mediator substance as described above (or its binding partner) generally bound to a solid phase to form a immunosorbent, or in the alternative, bound to a suitable tag;
(b) if necessary, other reagents; and
(c) directions for use of said test kit.
Additional kits may be formulated to take advantage of numerous extant immunological protocols and techniques, and suchmodifications are considered within the scope of the invention.
In yet another aspect of the invention, antibodies specific to the aforementioned mediator may be administered in pharmaceutical compositions in response to shock produced by viruses, bacteria, protozoa, etc. These pharmaceutical compositions comprise:
(a) a pharmaceutically effective amount of the antibody together with
(b) a pharmaceutically acceptable carrier. With the aid of suitable liquids, the antibodies may be used ininjection preparations in the form of solutions. These compositions may then be administered to a human in the above manner in shock-reducing amounts to dissipate, if not overcome, the effectsof the invasion/shock.
As an adjunct to the development of antibodies and their use in the techniques described above, the present invention extends to methods of treatment of various conditions, such as shock etc., that are found to exist as a result of undesirably high mediator substance activity in the mammalian host. In such instance, the method of treatment may include the detection of the presence and activity of the particular mediator substance, andthe subsequent administration of the appropriate antibody or antibodies to the host, in amounts effective to neutralize the undesired mediator substance activity.
Conversely, certain adverse conditions in mammals such a obesity, may result from excess anabolic activity. For example, obesity may be caused by undesirably high levels of activity of the anabolic enzymes lipoprotein lipase, acetyl Coenzyme A carboxylase and fatty acid synthease. The invention accordingly includes a method for treating obesity, comprising administering a mediator substance in an acceptable form, and in an amount effective to assist in restoring proper body weight. Administration of such treatment, however, would be under strict control by a physician, and the amount, manner and frequency of administration of the mediator would be carefully determined and constantly monitored.
In addition to treatment with antibodies raised by a mediator substance, the present invention includes an assay system, for the examination of potential substances, such as drugs, agents, etc. to inhibit the synthesis or activity of a mediator substance. As described earlier appropriate cell cultures such as the 3T3-L1 and the Friend virus transformed erythroleukemia cells may be initially treated with a particular mediator to inhibit the activity of a particular anabolic actor, after which the potential drug etc. may be added, and the resulting cell culture observed to determinewhether changes in the activity of the anabolic actor have taken place. Whilethe foregoing description makes reference to specific cell cultures for thepresent assay, it is to be understood that the invention is not limited thereto.
Certain compounds have already been screened, to determine whether or not each inhibited mediator production and/or the effect of the mediator. Compounds tested and the results ofsuch tests are set forth in the table, below.
TABLE
Mediator
Mediator
Entity
Production
Effect
Dexamethasone 10 −6 M
+
−
Aspirin 10 −3 M
−
−
Indomethacin 10 −5
−
−
Nalaxone 10 −5M
−
−
Thyroid Releasing Factor 10 −7 M
−
−
(+ denotes yes; − denotes no)
As can be seen, only dexamethasone seems to have any effect. And even dexamethasone only has an effect on “mediator” production and, thus, is only effective at the beginning of the process. Oncethe mediator has been produced, the dexamethasone does not seem tohave any further impact.
The following examples relate to the isolation of the mediator substance, and the observation of its activity, as related to certain anabolic enzymes etc. A review of the following should lend greater appreciation to the origins and potentials of the present invention. Naturally, however, the specific materials and techniques may vary, as explained earlier, so that the following is presented as illustrative, but not restrictive of the present invention.
It should be noted that the terms “mediator” and “mediator substance”, whether used in the singular or in the plural, are intended to refer to the same material that is isolated from macrophage cells that have been incubated with a stimulator material as disclosed herein, and both singular and plural usages of these terms, where present, should be viewed as equivalent for purposes of the present disclosure. At present, the exact composition of the mediator is unknown and, therefore, also unknown is whether the mediator is a single material or a mixture. Accordingly, the present terminology is intended to cover the “mediator” whether it is a single material or a mixture of materials. The term “mediator activity composition” and its plural may be distinct, as, although the mediator or mediator substance would be the same, the remainder of the composition may possibly vary depending upon the degree to which other cellular constituents, factors, etc. may be present therein.
EXAMPLE I
Isolation of Mediator Activity Compositions
A. Mice used in Testing:
Male C3H/HeN endotoxin sensitive mice (7-10 wk: 18-25 g) were obtained from Charles River Breeding Laboratory (Wilmington, Mass.). Male C3H/HeJ, endotoxin-resistant mice (7-10 wk: 18-25 g) were obtained from The Jackson Laboratory (Bar Harbor, Me.). Mice were fed ad libitum on Rodent Laboratory Chow (Ralston Purina Co., St. Louis, Mo.) until they were utilized. The chow diet was removed 24 hours prior to each experiment and replaced with a solution of 25% sucrose in water. The animals, once injected, were only allowed access to water. Three to 10 C3H/HeN or C3H/HeJ mice were employed in each experimental group.
In conducting the various experiments, each mouse was injected intraperitoneally with one of the following: (i) 0.04 to 100 μg of endotoxin; (ii) 0.5 ml of serum obtained from C3H/HeN mice treated with endotoxin or saline; (iii) 1 ml of medium from cultures of peritoneal exudate cells of mice incubated in the presence or absence of endotoxin. Animals were sacrificed by decapitation.
B. Assay for Serum Triglyceride Concentration and Tissue Lipoprotein Lipase Activity:
The triglyceride concentration was measured with an enzymatic assay (Triglyceride Test Set No.961, Hycel Inc., Houston, Tex.). Lipoprotein lipase activity was assayed by the methods of Pykalisto, et al., PROC. SOC. EXP.BIOL. MED., 148 at 297 (1975); and Taskinen, et al., DIABETOLOGIA 17 at 351 (1979), both incorporated herein, with some modifications. Epididymal fat pads were excised immediately after the decapitation of each mouse. The tissues were rinsed in sterile Dulbecco's Modified Eagle medium (DME) (Gibco, Grand Island, N.Y.) containing 2% bovine serum albumin (fraction V, Reheis Chemical Company, Phoenix, Ariz.) and blotted on sterile filter paper. The tissues were minced with scissors, put into pre-weighed sterilepolypropylene culture tubes (17×100 mm, Falcon Division of Bector, Dickinson and Company, Cockeysville, Md.) containing 1 ml of DDME medium supplemented with 2% bovine serum albumin, and 2 U of heparin to release LPL (Lipo-Hepin, Riker Laboratories, Inc.,Northridge, Calif.). Tubes with the tissues were sealed under 5% CO 2 , balance air and incubated at room temperature with continuous gentle shaking. Tissue weight was determined by the difference of the weights of the tube before and after the addition of the tissue. Approximately 100-300 mg of tissue was removed and the activity of lipoprotein lipase released from the tissue was determined.
The enzyme assay was carried out by the method of Nilsson-Ehle and Shotz, J. LIPID. RES. 17 at 536 (1976), incorporated herein, with minor modifications. The samples were incubated at 37° C. for 90 minutes of incubation. Each sample was assayed in duplicate. One milliunit of the enzyme activity was defined as one nanomole of free fatty acid released per minute. The enzyme activity released per gram of wet tissue was compared between experimental groups and control groups of each study since there was considerable variation of LPL activity day to day. In order tocompare the data between experiments, the data was expressed aspercent of the average activity of the control group. The rangeobserved in C3H/HeN mice was from 32 to 59 mU/g for adipose tissue Values of 31 of 172 mU/g for adipose tissue were observed in C3H/HeJ mice.
C. Collection of Serum for Endotoxin Treated Mice:
Blood was obtained under sterile conditions from the axillary pit of C3H/HeN mice 2 hours after i.p. injection of endotoxin (either 2 or 100 μg/mouse) in 0.1 ml of saline or saline alone. Serum was prepared within one hour after bleeding and either used immediately or kept at 80° C. until use.
D. Preparation of Endotoxin Treated Peritoneal Exudative Cells:
Peritoneal exudate cells were obtained by peritoneal lavage with pyrogen-free saline (Abbott Laboratories, NorthChicago, Ill.) from C3H/HeN mice (25-33 g). These mice were injected imp 6 days prior to lavage with 3 ml of sterile Brewer's thioglycollate medium (Difco Laboratories, Detroit, Mich.) to increase cell production. The peritoneal exudate cells obtainedby this procedure consist of approximately 60% macrophages, 20% small lymphocytes, 15% large lymphocytes, and 5% eosinophils.
The exudate cells (2×10 6 cells/well) were incubated in serum-free RPMI-1640 medium (Gibco, Grand Island, N.Y.) in culture plates containing 4.5 cm 2 wells at 37° C. in 5% CO 2 . After 3 hours, the cultures were washed three times with the medium to remove nonadherent cells. The cells which adhered to the dishwere mainly macrophages. In the various testing procedures, thecells were incubated in serum-free RPMI-1640 medium in the presence or absence of endotoxin (10 μg/ml). The culture medium was removed at 26 hours incubation and centrifuged at 1000 g for 5 minutes at 4° C. The supernatant was used for testing immediately or kept at −80° C. until required for testing. No difference in activity was noted after storage for one month under these conditions.
The various studies and isolation procedures will now be described.
E. Mediator Activity Produced in Mice:
The LPL activity from adipose tissue and the serum triglyceride concentration ofendotoxin-sensitive mice which had been injected with eithersaline (controls or 100 μg of endotoxin) 16 hours before sacrifice was observed. This amount of endotoxin corresponds in this strainof mice to a dose in which half the animals die within three daysafter injection. It was observed that the LPL activity of adiposetissue in the endotoxin-treated animals was depressed to 4.5% of the control values while the triglyceride concentration in theserum of the endotoxin treated animals were elevated 2.6 times that of control animals.
The fact that the lowering of LPL activity is to be attributed to mediator activity produced as a result of stimulation by endotoxin and not to the endotoxin itself is supported by the results obtained when the serum from endotoxin-sensitivemice which had been treated with 100 μg of endotoxin 2 hours prior to bleeding was injected into another group of endotoxin-sensitive mice. For this test, the control group was injected with serum obtained from another group of endotoxin-sensitivemice which had been injected with pyrogen-free saline. LPLactivity in epididymal fat pads were measured 16 hours later.
As further illustrated in FIG. 1A, the serum from endotoxin-treated mice markedly suppressed LPL activity in theseanimals compared to the activity in the control group of animals.Since greater than 90% of endotoxin is known to be cleared from circulation in 15 minutes, it is clear that the observed effect on LPL activity is not due to a direct effect on any remaining endotoxin present in the serum 2 hours after injection. It must be caused by a humoral factor or mediator produced as a result ofthe endotoxin injection.
To further exclude direct endotoxin effects, serum obtained from the sensitive C3H/HeN strain of mice which had been injected 2 hours previously with a smaller amount (2 μg) of endotoxin was injected into endotoxin-resistant C3H/HeJ mice. The LPL activity of adipose tissue was measured 16 hours after the injection to minimize the possibility of direct endotoxin effectand revealed a 55-percent decrease of LPL activity as illustrated in FIG. 1 B. Since resistant animals do not respond to thissmall amount of endotoxin, this observation again establishes that a humoral mediator is involved to which the resistant miceare capable of responding.
F. Mediator Activity Produced in Mice Peritoneal Exudate Cells:
Experiments were undertaken to show that exudate cells could be stimulated to produce the mediator by which endotoxinsuppresses the LPL activity of adipose tissue. Exudate cells were obtained from endotoxin-sensitive (C3H/HeN) mice by peritoneal lavage. These cells were incubated in vitro in the presence of 10 μg/ml or absence of endotoxin. One ml of the media from these cell cultures was injected into the endotoxin-resistant strain ofC3H/HeJ mice. As displayed in FIG. 2, the average LPL activity in adipose tissue of animals injected with medium from the exudatecells incubated with endotoxin was 32% of that of mice which received either medium from cell cultures without added endotoxin or medium containing endotoxin but without cells. The differencein enzyme activity between animals treated with medium from endotoxin treated cell cultures and those animals treated with saline alone was much greater than the other controls, suggesting that asmall amount of mediator was released by exudate cells in the absence of endotoxin and that the small amount of endotoxin in the medium without cells was enough to partially lower LPL activity.
From the above, it is clear that endotoxin administration markedly suppresses adipose tissue LPL in genetic strains of mice which are sensitive to endotoxin shock and death. Thisaction is mediated by humoral factor or factors which can suppressadipose tissue LPL in mice not sensitive to endotoxin shock, aswell as in mice which are sensitive. Peritoneal exudate cellssensitive to endotoxin are also capable of producing this humoral mediator
G. Isolation of Mediator Activity Compositions from Mouse Peritoneal Exudate Cells:
Culture medium is collected from mouse peritoneal exudate cells cultured in RPMI-1640 growth medium exposed to 10 μg/ml of endotoxin for 24 to 36 hours and centrifuged at 500 rpm for 10 minutes at 4° C. The supernatant is subjected to ultrafiltration through an Amicon PM-10 membrane with a 10,000-Dalton cut-off. The volume of the retentate is concentrated by filtration to approximately 7 ml, placed on a Sephacryl 300 column (1.695 cm) and eluted with phosphate-buffered saline (PBS) (pH 7.4) at 4 ml/hr and 4° C. The volume of each collected fraction was 3.6 ml. The fractions were analyzed for LPL activity. Fractions eluting at 108 to 115 ml and 133 to 140 ml were found to be active in the LPL assay. The molecular weights of the mediatoractive compositions in these fractions are about 300,000 and 70,000 Daltons, respectively.
The lyophylized filtrate from the ultrafiltration is dissolved in a minimal amount of distilled water, chromatographed on a Sephadex G 50 column (1.6×95 cm), and eluted with PBS (pH 7.4) at a flow rate of 6 ml/hr. Fractions of 3 ml were collected and analyzed for LPL activity. The activity was located in fractionseluting at 170 to 179 ml which corresponds to a molecular weight to about 400 to 1,000 Daltons.
The approximate molecular weights were determined in accordance with standard practice by comparison with proteins of known molecular weight. The standards employed were ferritin, molecularweight—440,000 Daltons; bovine serum albumin, molecular weight—68,000; carbonic anhydrase, molecular weight—30,000; and ribonuclease, molecular weight—17,000; all in Daltons. As is known to those skilled in the art, molecular weights determined by thisprocedure are accurate to about 20%.
Mediator activity compositions can also be isolated from mouse peritoneal exudate cells by vacuum dialysis using a Millexmembrane (Millipore Corporation, Bedford, Mass.) according to the following procedure.
Vacuum dialysis was carried out in dialysis tubing with molecular weight cut-offs at 13,000-14,000 Daltons. Samples of conditioned medium obtained from endotoxin-treated exudate cell cultures were placed under vacuum for 6 hours at 4° C. with a 40-percent reduction in volume. Aliquots from inside and outside the bag were assayed for mediator activity.
It was found that all of the activity was retained during vacuum dialysis with membranes having a 12,000-Dalton pore cutoff. The mediator composition isolated by this procedure, therefore, has a molecular weight greater than 12,000 Daltons. This composition contains the two higher molecular weight compositions previously described. The reason that the lowest molecular weight composition is not obtained is not clear. Possibly because it is absorbed in the Millex membrane or because the procedure with the Amicon filter is more rapid.
The stability of the various mediator compositions to heat was assessed by heating at 100° C. for 15 minutes. The inhibitory effect of the mediators on the lipoprotein lipase was completely abolished by this treatment.
To determine whether the mediators are intracellular constituents of nontreated cells, exudate cells were sonicated and the extract was assayed for mediator activity. These extracts had no measurable mediator. The mediators, therefore, are not a normal intracellular substance of exudate cells, but are synthesized or processed in these cells following stimulation by endotoxin.
The fact that the mediator activity compositions are in the tissue culture medium of tissue cultures of peritoneal exudate cells make it clear that they are water-soluble.
The mediators, therefore, are capable of reducing LPL activity in the mammalian body, can be isolated by standard procedures such as chromatography, dialysis and gel electrophoresis from the serum of endotoxin-treated animals or from a cell culture of peritoneal exudate cells incubated with endotoxin.
H. Studies of 3T3-L1 Preadipocytes:
The properties of the mediator compositions were further investigated using the well defined 3T3-L1 “preadipocyte” model system, by the inventors herein and co-workers, P. Pekala and M. D. Lane, 3T3-L1 preadipocytes, originally cloned from mouse embryo fibroblasts, differentiate in monolayer culture into cells having the biochemical and morphological characteristics of adipocytes. During adipocyte conversion, 3T3-L1 cells exhibit a coordinate rise in the enzyme of de novo fatty acid synthesis and triacylglycerol synthesis. Similarly, the activity of lipoprotein lipase, another key enzyme of lipid metabolism, rises 80-180 fold during adipose conversion. The activity of the enzyme is enhanced by the presence of insulin in the medium and appears to be similar to the lipoprotein lipase of adipose tissue.
Utilizing cells of the 3T3-L1 preadipocyte cell line, it was found that addition of the mediator compositions, derived from mouse peritoneal exudate cells exposed to endotoxin as described above, suppresses the activity of lipoprotein lipase.
The endotoxin used in the 3T3-L1 cell culture study was obtained as described above. Cell culture media and fetal calf serum were obtained from Gibco Laboratories (Long Island, N.Y.). 3-isobutyl-1-methylxanthine was from Aldrich Chemical (Milwaukee, Wis.), dexamethasone from Sigma Chemical Company (St. Louis, Mo.), and insulin from Eli Lilly Corporation (Arlington Heights, Ill.). Triolein was from Nu Check Prep, Inc. (Elysian, Minn.). Crystaline bovine serum albumin was from Calbiochem-Behring Corporation (LaJolla, Calif.).
I. 3T3-L1 Cell Culture:
3T3-L1 preadipocytes were cultured as previously described [MacKall, et al., J. BIOL. CHEM. 251 at 6462 (1976), and A. K. Student, et al., J. BIOL. CHEM., 255 at 4745-4750 (1980)] in Dulbecco's modified Eagle's medium (DME medium) containing 10% fetal calf serum. Differentiation leading to the adipocyte phenotype was induced by the Student, et al., modification of the method of Rubin, et al., [J. BIOL. CHEM. 253 at 7570-7578 (1978)]. Two days after confluence, the medium was supplemented with 0.5 mM isobutyl-methylxanthine, 1 μM dexamethasone and 10 μg of insulin per ml. Forty-eight hours later, the medium containing isobutyl-methylxanthine, dexamethasone, and insulin was withdrawn and replaced with medium containing insulin at a reduced concentration of 50 ng per ml.
J. Effect of Mediator Compositions on 3T3-L1 Cells:
One hour after the culture medium was replaced with medium containing the reduced concentration of insulin, conditioned media from cultured exudate cells with or without added endotoxin were added to 3T3-L1 cell cultures. Incubation of the cells with the conditioned medium was carried out for up to 20 hours. At indicated times, the amount of lipoprotein lipase activity was measured in three compartments: (1) the activity of the medium; (2) the activity released from the cells following incubation with heparin (this activity represents the enzyme associated with the outer surface of the cell membrane); and (3) intracellular activity.
Following the withdrawal of the medium, the dishes were rinsed once with fresh medium and the lipoprotein lipase associated with the cell membrane was released by incubation for one hour in DME medium supplemented with heparin (10 U/ml) and insulin (50 ng/ml). After removing this medium, the dishes were rinsed with PBS and the cells were scraped into 1 ml of 50 mM, NH 3 /NH 4 C1 buffer, pH 8.1 containing heparin 3 U/ml. The cell suspension was sonicated (on ice) for 15 seconds and centrifuged at 500×g for 5 minutes. The supernatant was assayed for lipoprotein lipase.
Lipoprotein lipase assays were performed within 30 minutes after the preparation of each sample in duplicate by the method of Nilsson-Ehle and Shotz [J. LIPID. RES. 17 at 536-541 (1976)] with minor modifications. Briefly, 75 μl of enzyme was mixed with 25 μl of substrate containing 22.7 mM[3H]-triolein (1.4 uCi per mole), 2.5 mg per ml of lecithin, 40 mg per ml bovine serum albumin, 33% (V/V) human serum and 33% (V/V) glycerol in 0.27 M Tris-HC1, pH 8.1, and incubated at 37° C. for 90 minutes. One milliunit of enzyme activity was defined as the release of one nanomole of fatty acid per minute. The lipase activity in all three compartments was inhibited >90% by addition of 1 M NaCl and >80% by omission of serum which is the source of apolipoprotein C-II needed for enzymatic activity.
To test the effect of the mediator on the lipoprotein lipase activity of 3T3-L1 cells, the conditioned medium obtained from mouse peritoneal exudate cells cultured in the presence or absence of endotoxin, was added to 3T3-L1 cells in monolayer culture. After a 20-hour incubation at 37° C., lipoprotein lipase activity was assessed in three compartments: (1) the culture medium; (2) the cell surface (heparin-releasable lipase activity) and; (3) the intracellular fraction.
As shown in FIG. 3, Cols. A & C, the addition of media containing the mediator substance from endotoxin-stimulated exudate cells, markedly suppressed the lipoprotein lipase activity in all three compartments. The enzyme activities in the medium, on the cell surface (heparin releasable), and in the intracellular compartment were 0.1%, 6%, and 18%, respectively, of that of the control cells incubated with the same amount of fresh RPMI-1640 medium. No difference in morphology or extent of adipocyte conversion was detected between cells in the experimental and control groups. At the beginning of the study, approximately 20% of the cells exhibited triglyceride accumulation in the cytoplasm; 20 hours later, approximately 50% of both the experimental and control cells had accumulated triglyceride.
The medium from the culture of exudate cells not treated with endotoxin had little effect on the lipoprotein lipase activity of 3T3-L1 cells. While the medium from untreated exudate cells elicited some inhibition in the study shown in FIG. 3, Col.B in other similar studies, medium prepared identically had no inhibitory effect. Endotoxin itself also had a negligible inhibitory effect on lipoprotein lipase activity when the amount added was equivalent to that which might remain in the conditioned medium from endotoxin-treated exudate cells; a 19%, 9%, and 0% decrease was observed on medium, heparin-releasable and intracellular compartments, respectively. The decrease was greater (45% in medium, 17% in heparin-releasable, and 11% in the cells) when larger amounts (4.5 times) of endotoxin was employed, as shown in FIG. 3, Column D.
A possible explanation for the decreased activity of lipoprotein lipase described above is a direct inhibitory effect of mediators on the enzyme. This was examined by incubating medium from 3T3-L1 cell cultures which contained lipoprotein lipase with conditioned medium from cultures of endotoxin-treated exudate cells. It was found that the enzyme activity was not inhibited by the mediator compositions (103% of the control) at the time of mixing, and the rate of decay of enzyme activity was the same in the experimental group and the control group. Endotoxin also had no effect on the activity of lipoprotein lipase. The results imply that the mediator compositions depress lipoprotein lipase activity in 3T3-L1 cells by inhibiting the intracellular synthesis or processing of the enzyme.
The relationship between the amount of mediator compositions and lipoprotein lipase activity of 3T3-L1 cells was examined by incubating the cells with increasing amounts of the conditioned medium from endotoxin-treated exudate cells for 20 hours at 37° C. Ten μl of conditioned media added to 1.5 ml of culture media was sufficient to cause a substantial decrease in lipoprotein lipase activity, i.e., 57% decrease in the medium, 40% decrease in the heparin-releasable compartment, and 8% decrease in the cells. Enzyme activity was further depressed by increasing the amount of mediator containing medium. When 250 μl were added, a decrease of greater than 95% was observed in all three compartments. The amount of mediator present in conditioned medium varied somewhat from preparation to preparation.
The rate at which lipoprotein lipase activity declines after the addition of the mediators was also investigated. Conditioned medium containing mediators was added at selected intervals, and lipoprotein lipase activity was measured. A reduction of lipase activity was apparent as early as 30 minutes after addition of 3T3-L1 cells. Approximately half of the intracellular enzyme activity was lost after 2.5 hours. After 5 hours of incubation with a mediator, a maximal effect was observed. The amount of enzyme activity in the medium and that on the cell surface were also observed to decrease with a similar time course (data not shown).
The rapid decrease in lipoprotein lipase activity might reflect a competition with insulin since removal of insulin has been shown to lead to a rapid decline in lipoprotein lipase activity in 3T3-L1 cells. However, an attempt was made to reverse the suppressive effect of the mediator by increasing the concentration of insulin in the medium was not successful. For this study, the effect of incubating 3T3-L1 cells with media containing insulin at various concentrations (50 ng/ml to 50 μg/ml) and mediator was assessed for lipoprotein lipase activity. It was found that the inhibitory effect of the mediator on enzyme activity was not changed with increasing insulin concentrations. Even at an insulin concentration 1,000 greater (50 μg/ml) than that of standard onditions (50 ng/ml), the inhibition was not reversed.
EXAMPLE II
Reasoning that other anabolic activities of the 3T3-L1 cells might be inhibited by the mediator, we studied two key enzymes: (1) acetyl CoA carboxylase; and (2) fatty acid synthetase; for de novo fatty acid biosynthesis. The following example based upon a manuscript in preparation by the inventors herein and co-workers, P. Pekala, M. D. Lane and C. W. Angus, presents evidence that the synthesis of these enzymes are also inhibited by the addition of the macrophage mediator. The results implicate a larger role for the mediator(s) and point to the presence of a communication system between immune cells and energy storage cells of mammals. Presumably, during invasion the immune cells can function as an endocrine system and selectively mobilize energy supplies to combat the invasion.
A. Materials:
Endotoxin (lipopolysaccharide) from E. coli 0127: B8 isolated by the method of Westphal, described supra, was purchased from Difco Laboratories (Detroit, Mich.). Cell culture media and fetal calf serum were obtained from Gibco Laboratories (Grand Island, N.Y.). 3-isobutyl-1-methylxanthine was from Aldrich Chemical (Milwaukee, Wis.); dexamethasone, from Sigma Chemical Company (St. Louis, Mo.); and insulin from Eli Lilly (Indianapolis, Ind.). IGG-SORB was from the Enzyme Center, Inc., (Boston, Mass.). L-[ 35 S]Methionine (800-1440 Ci/mmol) was from Amersham, En 3 Hance was obtained from NEN, (Boston, Mass.). Antiserum to fatty acid synthetase was kindly provided by Dr. Fasal Ashmad of the Papanicolau Cancer Research Institute, Miami, Fla.
B. 3T3-Ll Cell Culture:
3T3-L1 preadipocytes were cultured as previously described, [MacKall, et al., J. BIOL. CHEM. 251 at 6462 (1976)] in Dulbecco's modified Eagle's medium (DME medium) containing 10% fetal calf serum. Differentiation leading to the adipocyte phenotype was induced by the Student, et al., modification (A. K. Student, et al., J. BIO. CHEM. 255 at 4745-4750 (1980)) of the method of Rubin, et al., J. BIOL. CHEM. 253 at 7570 (1978). Two days after confluence, the medium was supplemented with 0.5 mM isobutyl-methylxanthine, 1 μM dexamethasone and 10 μg of insulin per ml. Forty-eight hours later, the medium containing isobutyl-methylxanthine, dexamethasone, and insulin was withdrawn and replaced with medium containing insulin at a reduced concentration of 50 ng per ml.
C. Preparation of Peritoneal Exudative Cells and Mediator Substances:
Peritoneal exudate cells were obtained by peritoneal lavage from C3H/HeN mice (25-33 g; Charles River Breeding Laboratories, Wilmington, Mass.) which had been injected intraperitoneally with sterile Brewer's thioglycollate medium (Difco Laboratories, Detroit, Mich.; 3 ml per mouse) 6 days prior to harvest. The exudate cells obtained using this procedure are primarily macrophages with some contaminating lymphocytes,
The cells (4×10 5 cells per cm 2 d ) were incubated in serum-free RPMI-1640 medium for 3 hours after which nonadherent cells were removed by washing 3 times with medium. Cells adhering to the dish were primarily macrophages. These cells were further incubated in serum-free RPMI-1640 medium in the presence or absence of 10 μg per ml of endotoxin. After 24 hours, the culture medium was removed and centrifuged at 1,000×g for 5 minutes at 4° C. The supernatant of conditioned medium obtained from cells exposed to endotoxin was assayed and found to contain the mediator substance that lowers LPL in 3T3-L1 cells.
No difference in activity was noted after storage of the conditioned medium for one month at −80° C.
D. Effect of Mediator on 3T3-L1 Cells:
One hour after the culture medium was replaced with medium containing the reduced concentration of insulin, conditioned media from cultured exudate cells with or without added endotoxin were added to 3T3-L1 cell cultures. Incubation of the cells with the conditioned medium was carried out for up to 20 hours.
E. Labeling of Cellular Proteins:
A 6-cm plate containing induced 3T3-L1 cells was washed twice with 5 ml of methionine-free medium and incubated for 1 hour with 2 ml of the same medium containing 0.5 mCi of L-[ 35 S]-methionine during which period the rate of [ 35 S]-methionine incorporation into cellular protein was linear. The medium was removed, the cell monolayer washed twice with phosphate-buffered saline, ph 7.4, and the soluble cytosolic proteins released by the digitonin method of Mackall, et al, supra. The remainder of the cell monolayer containing the membranous fraction was then scraped into 2.0 ml of 100 mM HEPES buffer, pH 7.5, containing 0.5% of the nonionic detergent NP-40 and 1 mM phenylmethylsulfonylfluoride. After trituration in a Pasteur pipet, the suspension was centrifuged at 10,000×g for 10 minutes at 4° C., and the supernatant saved.
[ 35 S]-methionine incorporation into acid insoluble material was determined by adding 20 μl of digitonin or NP-40 released material to 0.5 ml of ice cold 20% TCA with 25 μl of 0.5% bovine serum albumin added as carrier. After sitting at 4° C. for 1 hour, the mixture was centrifuged at 2,000×g for 5 minutes. The pellet was incubated in 0.5 ml of 1 M NH 4 OH at 37° C. for 30 minutes. The protein was reprecipitated on addition of 5.0 ml of ice cold 10% TCA and filtered on Whatman GF/C filters. The filters were extracted with diethyl ether and the amount of radiolabel determined.
F. Immunoadsorption Electrophoresis:
Aliquots of the soluble [ 35 S]-methionine-labeled proteins from the soluble (digitonin released) fraction of the cell monolayer were made 1 mM in PMSF and 0.5% in NP-40 detergent and then added to 5-1 of either antisera specific for acetyl CoA carboxylase, or fatty acid synthetase,
After 2 hours at 25° C., 100 μl of 10% IgG-SORB were added and the labeled enzymes isolated from the mixture by the method of Student, et al., supra. Polyacrylamide-SDS gels were run according to the method of Laemmli, and prepared for fluorography by use of En 3 Hance according to the manufacturer's instructions.
G. Results—Effect of Mediator on Acetyl CoA Carboxylase and Fatty Acid Synthetase:
To examine the effect of the mediator substance on the activities of acetyl CoA carboxylase and fatty acid synthetase enzymes, 3T3-L1 cells were exposed to conditioned medium from mouse peritoneal exudate cells cultured in the presence of endotoxin. After incubation of the 3T3-L1 cells with the mediator for 3, 6 and 20 hours, acetyl CoA carboxylase and fatty acid synthetase activities were determined on a digitonin released cytosolic fraction of the cells (FIG. No. 4 ). The activity of both enzymes decreased over the 20-hour period to approximately 25% of the initial values.
To determine if the loss in activity of the two enzymes was a result of a direct effect on protein synthesis, 3T3-L1 cells were incubated with conditioned medium from cultures of endotoxin-treated exudate cells for 3, 6, and 20 hours. During the final hour of incubation, the cells were exposed to a pulse of 35 S-methionine. Following the pulse, 35 S-methionine labelled acetyl CoA carboxylase and fatty acid synthetase were isolated from the digitonin releasable cytosolic fractions by immunoadsorption. Identification was accomplished by SDS-polyacrylamide gel electrophoresis and fluorography (FIGS. No. 5 A and 6 A). The decreased incorporation of 35 S-methionine into immunoadsorbable acetyl CoA carboxylase and fatty acid synthetase with respect to time following exposure to the mediator is readily observed. Densitometric scanning of the autoradiograms (FIGS. No. 5 B and 6 B) indicated that after 20 hours of exposure to the mediator, the amount of 35 S-methionine incorporated into fatty acid synthetase and acetyl CoA carboxylase were decreased by 80% and 95% respectively. These results are consistent with the concept that the mediator depresses the activity of acetyl CoA carboxylase and fatty acid synthetase by interfering with the synthesis of the enzyme.
H. Effect of Mediator on Protein Synthesis in General:
The observed effect on acetyl CoA carboxylase and fatty acid synthetase could be explained by a general inhibition of protein synthesis by the mediator. To examine this possibility, the effect of mediator on amino acid incorporation into protein was investigated. 3T3-L1 cells were incubated for various periods of time with conditioned medium obtained from mouse peritoneal exudate cells cultured in the presence of endotoxin. 35 S-methionine incorporation into soluble and membrane associated protein was determined after 1, 3, and 6 hours of exposure of the cells to the added factor. When 3T3-L1 cells were exposed to conditioned medium from mouse peritoneal exudate cells that were cultured in the absence of endotoxin, no effect on 35 S-methionine in incorporation into acid insoluble protein was observed. However, as seen in FIG. No. 7 , 35 S-methionine incorporation into TCA precipitable material in the soluble fraction (Digitonin releasable protein) increased approximately 10% in the first 3 hours with no further change observed, while a 50% decrease was observed for label incorporation into acid insoluble material in the membrane fraction (NP-40 solubilized protein). Analysis of 35 S-methionine labeled proteins following exposure to the mediator was accomplished utilizing SDS-gel electrophoresis. The pattern of the autoradiogram of the soluble proteins obtained on digitonin treatment and those solublized by NP-40 of the 3T3-L1 cells are shown in FIGS. No. 8 and 9 . Closer inspection of FIG. No. 8 reveals the gradual disappearance with time following the addition of the mediator of a protein band with a molecular weight of 220,000 Daltons, while another band appears at approximately 18,000. In addition to these major changes, another new protein appears at approximately 80,000 while a second protein of 50,000 disappears.
Analysis of the NP-40 solubilized proteins showed similar results (FIG. No. 9 ). Protein bands of molecular weights of approximately 80,000 and 30,000 Daltons appeared while bands of approximately 220- and 50,000 disappeared.
The loss of a protein band with molecular weight 220,000 in the digitonin releasable protein, is consistent with the loss of immunoadsorbable acetyl CoA carboxylase and fatty acid synthetase. The enzymes have similar molecular weights and under the conditions of this electrophoresis migrate with the same Rm. At present, it is not possible to identify the other protein bands with known enzymes or proteins.
I. Analysis.
The mediator appears to decrease enzymatic activity by suppressing the synthesis of the enzymes. The effect on protein synthesis appears to be quite specific as there are no gross perturbations of the protein patterns observed on the autoradiograms (FIGS. No. 8 and 9 ). In response to the mediator, the synthesis of several proteins is inhibited or induced. It was possible by immunoprecipitation to identify fatty acid synthetase and acetyl CoA carboxylase (M.W. 220,000) as two proteins whose synthesis is inhibited by the mediator. The identification of the other proteins that are modulated by the mediator is not possible at present, although lipoprotein lipase is a potential candidate for the 50,000-Dalton protein that appears. The nature of proteins that are induced in response to the mediator and the mechanism for the modulation of specific protein synthesis are deserving of further improvement investigations.
Whether the mediator responsible for regulating the synthesis of acetyl CoA carboxylase and fatty acid synthetase is the same as the mediator that suppresses the activity of lipoprotein lipase is not presently known. The relationship of these mediator(s) to the leukocyte factor that has been reported to metabolize amino acids from muscle to the liver is of considerable interest since this factor also imparts a catabolic state on the tissue.
EXAMPLE III
In this series of investigations, also embodied in an unpublished manuscript in preparation by the inventors herein, and co-worker Shigeru Sassa, we sought to determine whether the macrophage mediator(s) observed in Examples I and II exerted any effect upon red blood cell synthesis. We reasoned that, as anemia is commonly observed in mammals afflicted with chronic infections, and that as regeneration of the red cell mass constitutes a potential drain on energy and amino acids, the body in response to acute invasion may interrupt erythroid development in similar fashion and perhaps by the same mechanism observed with respect to the anabolic enzymes lipoprotein lipase, acetyl Coenzyme A carboxylase and fatty acid synthetase, that affect adipocytes.
To evaluate this hypothesis, we examined the effects of endotoxin-induced factor(s) from mouse macrophages on the cellular proliferation and differentiation of a model erythroid progenative cell—the Friend virus- transformed erythroleukemia cells (See Friend, C. et al and Marks, P. A. et al., supra.). In this model system, cells can be induced to differentiate and form hemoglobin in response to a number of inducers, such as dimethylsulfoxide, (Friend, C., et al supra.), hexamethylenebisacetamide (Reuben, R. C. et al, PROC. NATL. ACAD. SCI., U.S.A., 73: 862-866),butyric acid, (Leder, A. et al (1975) Cell 5:319-322), and hypoxanthine (Gusella, J. F. (1976) Cell 8:263-269). This example presents evidence that a macrophage mediator(s) can inhibit the growth and differentiation of erythroid committed cells, but has less effect on uncomitted stem cells and practically no effect on fully differentiated erythroid cells.
A. Materials:
Endotoxin (lipopolysaccharide) from E coli 0127: B8 isolated by the method of Westpal (described supra.), was purchased from Difco (Detroit, Mich.). A modified F12 medium was prepared in our laboratory (Sassa, S. et al, J. BIOL. CHEM. 252: 2428-2436 (1977)). Fetal bovine serum was purchased from GIBCO (Grand Island, N.Y.). Dimethylsulfoxide(Me 2 SO) was a product of Eastman Organic Chemicals (Rochester, N.Y.). Butyric acid and hypoxanthine were obtained from Sigma Chemical Company (St. Louis, Mo.). Hexamethylenebisacetamide (HMBA) was kindly provided by Dr. R. C. Reuben, Merck Sharp & Dohme Research Laboratories (Rahway, N.J.).
B. Cell Culture:
Murine Friend-virus transformed erythroleukemia cells (clone DS-19) were cultivated in modified F12 medium supplemented with 10% heat inactivated fetal bovine serum as described previously (Sassa, S.,Granick, J. L.,Eisen, H. and Ostertag,W. (1978). In In vitro Aspects of Erythropoiesis, ed. by Murphy, M. J. Jr. (Springer-Verlag, New York) pp. 268-270).
C. Preparation of the Endotoxin-Stimulated Conditioned Medium From the Culture of Mouse Exudative Cells:
Isolation of peritoneal exudate cells from NCS mice (25-33 g from the Rockefeller University Breeding Colony) and preparation in vitro of an endotoxin-stimulated conditioned medium were carried out as described (in Example I, above). Briefly, peritoneal exudate cells were isolated from mice treated with sterile Brewer's thioglycollate medium obtained from Difco Laboratories (Detroit, Mich.),in an amount of 3 ml per mouse, 6 days prior to harvest. The cells were incubated in serum-free RPM1-1640 medium for 3 hours, after which non-adherent cells were rinsed off by washing three times with medium. Cells adhering to the dish were primarily macrophages (Kawakami et al., PROC. NATL. ACAD. SCI., USA 79:912-916; Edelson, P. S. et al., J. EXP. MED., 142:1150-1164 (1975)).
These cells were further incubated in the serum-free medium in the presence of endotoxin (5 μg/ml) for 24 hours. After incubation, the culture medium was removed and centrifuged at 1000×g for 5 minutes at 4° C. The supernatant of the conditioned medium contained an endotoxin-induced mediator which decreased the activity of lipoprotein lipase in 3T3-L1 cells (as reported in Example I, above) and was used without further treatment.
D. Induction of Erythroid Differentiation:
Two types of incubation protocols were used to assess erythroid differentiation of Friend cells. In certain experiments illustrated in FIGS. 10-13, the cells (5×10 4 cells/ml) were incubated at 37° C., in 5% CO 2 in humidified air for 18 hours. The inducing chemicals, e.g. Me 2 SO, HMBA, butyric acid, hypoxanthine or hemin were added with or without macrophage mediator(s) and cultures were incubated for 96 hours without changing the growth medium. In other experiments such as those with results illustrated in FIG. 14, the cells (10 5 cells/ml) were incubated for 18 hours, then Me 2 SO and the macrophage mediator were added as above. The cultures were maintained at 2×10 5 cells/ml by diluting the cell suspension daily with fresh medium containing the chemical inducer with or without the macrophage mediator. This procedure required more macrophage mediator than the first experimental procedure, but made it possible to examine the effect of mediator on rate of cell growth while cells were growing logarithmically at a constant rate (Chang, C. S. et al; J. BIOL. CHEM. 257:3650-3654 (1982)).
E. Determination of Heme Content and Assays on the Activities of Enzymes in the Hene Biosynthetic Pathway:
The concentration of heme in cells was determined by a fluorometric assay of porphyrin derivatives after the removal of iron (Sassa, S., Granick, S., Chang, C. and Kappas, A., In Erythropoisis, ed. by K. Nakao, J. W. Fisher and F. Takaku (University of Tokyo Press, Tokyo, Japan (1975) pp. 383-396). Cells containing hemoglobin were stained with benzidine and counted using a Cytograf model 6300A (Sassa, S. Granick, J. L., Eisen, H., and Ostertag, W., Supra.). Assays of aminolevulinic acid (ALA) dehydratase and porphobilinogen (PBG) deaminase were carried out by methods described previously (Sassa, S., Granick, J. H., Eisen, H., and Ostertag, W., Supra.).
F. Effects of the Macrophage Mediator on the Growth and Differentiation of Uninduced Friend Cells:
Conditioned media from macrophage cultures incubated with or without endotoxin inhibited the growth of untreated Friend cells by approximately 35% (FIG. 10, Part A.). When these cells were incubated simultaneously with 1.5% Me 2 SO, control conditioned medium which had not been exposed to endotoxin inhibited the cell growth by ˜42% while endotoxin-stimulated conditioned medium inhibited the growth of ˜60% (FIG. 10, Part B).
Heme content in these cells treated with endotoxin-stimulated or non-stimulated conditioned media was not appreciably different from that found in untreated cells, indicating that the conditioned medium by itself does not affect the erythroid differentiation of Friend cells (FIG. 10, Part B), In contrast, incubation of cells with Me 2 SO and endotoxin-stimulated conditioned medium led to a significant decrease (˜40%) in the heme content in the cell (FIG. 10, Part B).
G. Dose Dependent Inhibition of Cell Growth and Differentiation By the Macrophage Mediator:
When Friend cells were incubated simultaneously with 1.5% Me 2 SO and the endotoxin-stimulated macrophage mediator, the rate of cell growth was progressively inhibited when increasing amounts of the mediator were added to the culture (FIG. 11, Part A). An inhibitory effect of the mediator on cell growth could be detected at the lowest concentration examined (1.12 vol. % added to growth medium), At the highest concentratio (8 vol. %), the mediator inhibited cell growth by ˜60% compared with that of the control Me 2 SO-treated culture (FIG. 11, Part A). The decrease in cell number was not due to cell death since the number of dead cells as assessed by the Trypan Blue exclusion test (Paul J. In Cell Culture) was similar (˜8%) for untreated controls and cultures treated with the stimulated conditioned medium. Endotoxin itself (up to 15 μg/ml) exhibited no inhibitory effect on the growth of Friend cells either in the presence or in the absence of Me 2 SO (data. not shown). These findings indicate that the endotoxin-stimulated macrophage mediator interferes with the growth of Me 2 SO-treated cells more than that of untreated cells and suggest that erythroid committed cells may be more sensitive than uncommitted stem cells to the action of the stimulated macrophage mediator.
Treatment of cells with the endotoxin-stimulated macrophage mediator inhibited Me 2 SO-mediated erythroid differentiation resulting in a progressive decrease in the content of porphyrin and heme in the treated cells as the amount of the mediator increased, (FIG. 11, Part B.) The enzymatic activities of ALA dehydratase and PBG deaminase were also decreased by the mediator treatment (FIG. 11, Part B). The addition of the macrophage mediator directly to the enzyme assay mixture did not inhibit the activity of ALA dehydratase or PBG Deaminase(data not shown), ruling out a direct inhibitory effect on the activities of the enzymes.
H. Delayed Addition of the Endotoxin-Stimulated Macrophage Mediator on Erythroid Differentiation:
When the endotoxin-stimulated conditioned medium was added to Me 2 SO-treated cultures at various times, it was found that the effect of the macrophage mediator on cell growth was gradually lost (FIG. 12 ).
The effect of the macrophage mediator on erythroid differentiation decreased more rapidly than the effect on cell growth. For example, the addition of the endotoxin-stimulated macrophage mediator inhibited heme and protoporphyrin formation by ˜40% at the beginning of incubation, ˜25% when added at 24 hours, and had no effect when added at 48 hours or after. Inhibition of the activity of ALA dehydratase and PBG deaminase by the macrophage mediator treatment was also progressively diminished when the mediator was added later during incubation (FIG. 12 ).
These findings indicate that, in contrast to the macrophage-mediator dependent inhibition of cell growth and differentiation observed in erythroid-committed cells, cells which have fully expressed erythroid characteristics such as those exhibiting maximal increases in the activities of ALA dehydratase and PBG deaminase, or in the contents of protoporphyrin and heme, are considerably less sensitive to the inhibitory effect of the macrophage mediator.
I. Effects of the Endotoxin-Stimulated Macrophage Mediator on Erythroid Differentiation of Friend Cells Induced by HMBA, Butyric Acid, Hypoxanthine or Hemin:
In order to examine whether or not the inhibitory effect of the endotoxin-stimulated macrophage mediator on erythroid committed cells is specific for Me 2 SO-induced differentiation, we examined the effect of the macrophage mediator on cells which were incubated with either HMBA, butyric acid, hypoxanthine or hemin. We found that the endotoxin-stimulated macrophage mediator markedly inhibited the growth of cells incubated with HMBA, butyric acid or hypoxanthine, but not the growth of hemin-treated cells (FIG. 13, Part A). Similarly, the endotoxin-stimulated mediator inhibited the erythroid differentiation induced by HMBA, butyric acid or hypoxanthine, but not that induced by hemin treatment (FIG. 13, Part B).
These findings suggest that the inhibitory action of the endotoxin-stimulated macrophage mediator on the growth of erythroid-committed cells and erythroid differentiation induced by most of the chemical agents as represented by Me 2 SO, HMBA, butyric acid or hypoxanthine is similar, but that erythroid differentiation induced by hemin treatment is distinct in nature and not sensitive to the effect of the macrophage mediator. In fact the growth inhibition of Me 2 SO-treated cells produced by the macrophage mediator alone (35%, FIG. 10) was completely overcome by hemin treatment (FIG. 13 ).
J. Effect of Endotoxin-Stimulated Macrophage Mediator on the Growth and Differentiation of Friend Cells Growing at a Constant Rate:
In order to examine the effect of the macrophage mediator on the growth of Friend cells while they are growing at a constant rate, cells were diluted with fresh medium with or without the mediator every 24 hours to reduce the cell density to 2×10 5 cells/ml.
Under these conditions of culture, the cells maintain a continuous logarithmic growth at a constant rate (Chang, C. S. et al supra.). The total number of cells that would have formed from the original untreated control culture was 82×10 6 cells/ml after 96 hours of incubation (FIG. 14 ). The addition of the macrophage mediator significantly inhibited (˜70%) cell growth. The addition of Me 2 SO to the cultures yielded 42×10 6 cells/ml. This decrease probably reflects the growth cessation which is associated with terminal erythroid differentiation of these cells. (Chang, C. S. supra.; Lo, S. C., Aft, R. and Mueller, G. C., Cancer Res. 41: 864-870 (1981)). Combined addition of Me 2 SO and the macrophage mediator produced the most profound growth inhibition (˜90%) of these cells. Heme content in cells treated with the mediator alone was not appreciably affected while the combined treatment with the mediator and Me 2 SO brought about ˜40% inhibition of heme formation.
K. Analysis:
The mediator substance under study appears to potently inhibit the growth and erythroid differentiation of mouse Friend-virus transformed cells. Conditioned medium from cultures not exposed to endotoxin had some inhibitory effects, but the effect of the endotoxin-stimulated conditioned medium is significantly greater in inhibiting the growth and differentiation of Friend cells. Endotoxin itself had no effect on either cell growth or differentiation.
Further,the effect of the mediator appears to be specific to certain stages of erythroid progenitor cells, in that the macrophage mediator inhibited the growth and erythroid differentiation of uncommitted stem cells more than that of erythroid committed cells which were induced by treatment with Me 2 SO, HMBA, butyric acid or hypoxanthine. The inhibitory effect of the macrophage mediator on cell growth was more pronounced in cells growing logarithmically at a constant rate. Hemin treatment of Friend cells is known to cause erythroid cell maturation leading to the appearance of hemoglobinized cells but without accompanying the commitment of undifferentiated stem cells to the erythroid precursor cells (Gusella, J, F., Weil, S, C., Tsiftsoglon, A. S., Volloch, V., Neuman, J. R. and Housman, D. (1976) Blood 56:481-487). Interestingly, the endotoxin-stimulated macrophage mediator also had very little effect on the growth and differentiation of Friend cells in the presence of hemin.
These results indicate that the endotoxin-stimulated macrophage mediator exerts its inhibitory effect on the growth and differentiation of cells of erythroid precursor cells including those which have been committed to undergo erythroid differentiation. On the other hand, cells which have fully expressed characteristics of erythroid cells such as increased activities of ALA dehydratase and PBG deaminase, and increased contents of protoporphyrin and heme are no longer sensitive to the inhibitory effect of the conditioned medium. Thus it appears that the action of the endotoxin-stimulated conditioned medium is relatively specific to certain early stages of erythroid precursor cells but not to fully differentiated erythroid cells.
We have also attempted to purify the mediator from the endotoxin-stimulated macrophage conditioned medium and found that a highly purified mediator retained the inhibitory property both on lipoprotein lipase activity in 3T3 cells and on the growth and differentiation of Friend cells.
The macrophage factor described in this Example is believed to play a role in the pathogenesis of the anemia associated with endotoxemia or other chronic disease states, e.g., cancer, rheumatoid arthritis, where the activity of the reticuloendothelia system is stimulated. The Friend cell system described here should be useful to detect such in vivo mediators and to elucidate the biochemical basis for the cellular effect of the mediator(s). This assay system should also aid the isolation of this factor and the identification of its relationship with other immune cell factors which are produced in response to invasion. | Provided are therapeutic uses of antibodies capable of neutralizing the adverse effects in humans of the about 70 kDa mediator produced upon invasive stimulation of macrophages by, e.g., contact with endotoxin. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a non-provisional continuation-in-part application claiming priority to provisional application No. 60/786,122, entitled Hand Held Sliding Surface For Snow Sports Used With Or Without Snow Ski Pole, Also Convenient For Hand Protection And Resting On While Stationary, filed on Mar. 27, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to snow sports such as snowboarding and alpine and cross country skiing.
2. Description of the Prior Art
Skiing has become an extremely popular sport throughout the mountainous regions of the world and lends great entertainment value to the participants. The sport is fraught with risk of injury. Those risks have been long recognized and have been addressed in many different ways, as by supplying safer skis, ski bindings and ski boots which afford support to the athlete and provide for release in the event of a fall or lose of control all in effort to minimize injury to the skier. Likewise, in snowboarding many improvements have been made to protect the lower extremities by providing for articulation of the boot mounts and release thereof.
In the meantime, little attention has been given to the injuries of the upper extremities during a high speed fall or loss of control.
Downhill skiers typically use long ski polls for support with handles at the top and baskets at the lower extremity to limit penetration into the snow of the pole tip. Some attention has been given to the injuries to the skiers hand and thumb from falls causing a forceful disengagement of the skiers hand from the pole and the safety strap attaching the hand to the pole.
Consequently, skiers, and particularly snowboarder's, have been left without meaningful protection against injury of the upper extremities during a fall when the skier's natural inclination is to reach his or her arm out toward the snow surface during the fall causing abrupt and violent contact with the snow thus resulting in the hand, wrist, elbow and often times shoulder injury from the sharp impact, frequently resulting in hospitalization and often times surgery.
It has been proposed to form a ski pole handle with a strut hand hold projecting laterally from the upper end thereof and turning downwardly to project parallel to the handle and form a narrow longitudinal runner. A device of this type is shown in U.S. Pat. No. 3,862,765 to Goheen.
While providing some support for certain exhibition maneuvers wherein the skier is facing forwardly and might lean over and apply weight to the runner as it moves along the hard pack snow surface, such devices have not been generally accepted and have little utility should a skier or snowboarder take a fall impacting the snow in a disorganized manner, sometimes inverted or facing uphill, resulting in disengagement from the ski pole itself.
SUMMARY OF THE INVENTION
The present invention includes a small ski having a hand hold thereon to allow the ski to be portably carried by a snowboarder during a downhill run and allowing the snowboarder to engage the ski against the snow to, as high speed downhill travel progresses, slide the ski along the surface of soft snow or the like to partially support continued downhill travel and minimize the prospects of abrupt high forces to the skier's arm and/or shoulder during a fall.
Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hand held ski appliance of the present invention;
FIG. 2 is a side view thereof in enlarged scale;
FIG. 3 is a left hand end view thereof partially in sections;
FIG. 4 is a right hand end view thereof partially in sections;
FIG. 5 is a top view thereof of the hand held ski appliance shown in FIG. 5 ;
FIG. 6 is a side view, in reduced scale, of a pair of hand held ski appliances shown in FIG. 1 and depicting a snowboarder resting thereon;
FIG. 7 is a side view of a second embodiment of the hand held ski appliance of the present invention;
FIG. 8 is a side view depicting a third embodiment of the hand held ski appliance of the present invention; and
FIG. 9 is a side view of a fourth embodiment of the hand held ski appliance of the present invention as incorporated in a ski pole.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3 , the protective ski appliance of the present invention includes, generally, a short ski 15 on the order 6″-18″ inches long and formed with a downwardly facing typically flat planar surface 17 and configured on at least one end with an upturned shovel 19 . A handle, generally designated 21 is surmounted on the ski 15 by means of one or more struts, generally designated 23 and 24 to project parallel to the ski. Thus, a snowboarder or the like using the appliance may grasp one in each hand, about the respective handle 21 , and embark on a snowboard adventure down the slops. In the event of a loss of control, fall or the like, the natural reaction of the snowboarder is to extend his or her arm to engage the underlying snow during a fall in effort to break the impact. With the appliance of the present invention, the ski 15 will absorb the impact as it contacts the snow surface to slide there along thus breaking up the force vector which would otherwise be applied to the arm and shoulder of the snowboarder thereby tending to break the fall and minimize forces on the snowboarder's arm, including the elbow and shoulder to thereby minimize injury from the impact.
With the current popularity of snowboarding and exhibition skiing, often times selected areas of a ski slope are set aside for special grooming, jumps, half pipes and the like thereby inducing athletic skiers and snowboarder's to undertake acrobatic maneuvers often times resulting, particularly during practice runs, in uncoordinated landings which redirect the snowboard or the skis in abrupt fashion thus leading to what can sometimes be a catastrophic fall. The tendency of the snowboarder or skier is to extend the downhill arm which, upon impact with the snow surface, can result in application of a high magnitude of inertia from the skier's body being applied to the arm and shoulder area. This impact often leads to significant injury to the skier's upper extremities, shoulder and sometimes the clavicle.
Typically, snowboarder's do not use ski poles or the like thus leaving them totally defenseless for any break in the fall or reduction in forces applied to the upper extremities upon impact. It is this situation to which the present invention is directed.
Skiers and snowboarder's typically maneuver over numerous various terrain involving different undulations and incline undertaking turns and maneuvers, often times attracted by looser snow and powder along the sides of a run where falls may well take place. It is desirable that the appliance of the present of invention provide for support in sliding relationship along the top surface of the loose snow or powder without the arm or hand digging deeply into the powder, an occurrence which could contribute to an application of abrupt force tending to dislocate the affected arm member.
As appreciated by those skilled in the art, the short ski 15 should have sufficient ski surface on the underside to provide support in sliding over soft or loose packed powder or over otherwise loose snow without digging into the loose snow and providing resistance to downhill skidding of the ski.
As will appreciated by those skilled in the art, the ski 15 must thus have sufficient supporting surface to maintain sliding support even during a fall when the entire weight of the snowboarder or skier might be applied to the ski. While the ski may take many different configurations and dimensions to provide the support surface, it is believed that an overall length of about 6 inches is required for the support surface 17 and up to about 18 inches, with a preferred length of about 9 or 10 inches being desirable, with a width of some substantial dimension, as for instance, at least 2½ inches and up to about 5 inches over all, preferably about 4 inches at the widest point. A minimum support area of about 15 square inches provides favorable performance. The ski itself may be made of conventional ski composites, wood, metal or any other desirable well known material.
The ski is preferably constructed with an upturned shovel 19 on at least one end and will typically be carried by the skier or snowboarder facing downhill in the direction of travel so that, in event of a fall, the forwardly facing skier will tend to extend the downhill arm and typically engage the ski shovel 19 facing downhill in the direction of travel to thus prevent the ski itself from digging into the snow and tending to induce the ski to ride up over the top of any loose snow or powder. In the preferred embodiment, the ski is configured with shovels 19 on both ends to thereby provide a double ended ski in the event so that the user may hold the ski without consideration without orientation in a direction facing downhill. Also, with a double ended ski, 15 in the event the skier or snowboarder embarks on a fall sometimes referred to as a “windmill”, the ski will be effective upon impact when facing in either direction of travel so as to ride up over the top surface of the snow. The underside of the ski if formed with a longitudinal directional groove 30 .
Referring to FIG. 4 , the struts 23 may be constructed of resilient, compressible material such as plastic or spring metal to, under a predetermined load, such as that typically with risk of shoulder injury i.e. about 50 lbs. to flex and absorb some of the load as the struts 23 flex from the fully extended position shown in FIG. 3 to the shock absorbing position shown in FIG. 4 .
Referring to FIGS. 1 , 2 and 6 , in the preferred embodiment, the ski appliance of the present invention includes an axle projecting from the handle 21 and mounting a miniature seat, generally designated 35 supported over the strut 24 and nested over the ski inside the upturn tip of one of the shovels 19 .
In use, it will be appreciated that the protective ski appliances of the present invention may be conveniently packed with the user's boots or otherwise in his or her travel luggage or backpack to be available at the ski slope. When the snowboarder or skier reaches the ski slope, he or she may reach into his or her backpack and retrieve the protective ski appliance for use in a downhill run. When a downhill run is to be commenced, the snowboarder skier may grasp an appliance in each hand and maneuver the hands freely during the run as is normal for a snowboarder. As a snowboarder leans to one side or the other of the board it will be appreciated that the appliance may be extended toward the snow to provide for lateral support during any acrobatic maneuvers and may even be utilized to facilitate extreme exhibitionist moves.
In the event of a fall or the like, the snowboarder will want to retain a grasp on the handles 21 and he or she will typically inherently be induced to extend the hand on the side toward which the fall is underway thus extending the ski 15 on that side toward the snow surface. In the event, the snowboarder completely leaves his or her feet it will be appreciated that the entire force generated by the momentum of the snowboarder hurdling down the slope, will cause the downhill ski to engage the snow surface with tremendous force. The snowboarder will endeavor to direct the ski appliance longitudinally along the snow surface in the direction of the momentum of the fall. The initial engagement of the ski 15 at high speeds with the surface of the snow, even for loose, packed or powder will tend to cause the shovel 19 at the downhill end of the ski 15 to ride along the snow surface and be elevated there along to be maintained on the top surface of the snow to thus provide for sliding of the ski 15 and avoid abrupt stop or diving deep into the snow surface which might otherwise generate trauma in the snowboarder's arm and/or shoulder.
It will be appreciated that the initial force typically takes place directed in a downward direction along the incline thus causing the ski to impact the inclined snow surface moving downwardly along the direction of the fall. The groove 30 will cooperate in tending to keep the ski directed in the desired orientation on the snow as dictated by the orientation of the handle carried in the user's hand.
The force of impact which may well be on the order or a couple of hundred pounds will typically be broken up into a somewhat vertical component perpendicular to the angle of the incline and somewhat horizontal component along the direction of the incline. This breaking down of the impact forces will tend to minimize the shock on the snowboarder's extended arm and consequent trauma to the arm and shoulder.
As the snowboarder progresses on downhill during the fall, the force applied to the protective ski appliance will be reduced due to the decrease in momentum thus tending to dissipate the dangerous and injurious forces which would otherwise be experienced.
For situations where the initial impact might be directed along a force more perpendicular to the snow surface, the overall force may well exceed 100 lbs. or more. To facilitate absorption of those forces, the struts 23 and 24 are constructed such that, at about 50 lbs. of force, they tend to flex, bend, or otherwise contract to absorb the impact forces in a spring like manner to reduce or eliminate trauma to the arm and shoulder ( FIG. 4 ).
As the ski 15 is directed along the downwardly inclined path of travel, the groove 30 will tend to capture a ridge of snow under the ski surface 17 to thus cooperate in maintaining a direction of travel longitudinal to the ski itself thereby minimizing erratic and dangerous unwanted turning of the ski relative to the snowboarder's arm.
In the preferred embodiment, the ski 15 is contoured in somewhat of an hour glass shape along the opposite edges thereof to facilitate turning thereof in the event the user elects to turn the ski on the snow surface, by twisting of his or her hand either in an acrobatic maneuver or during a progressive fall to maintain the desired direction of travel.
As will be appreciated by those participating in the sport, snowboarder's face the difficulty that, unlike skier's who typically have long poles to lean on, have limited resources to facilitate resting during there decent. Often times snowboarder's are forced to merely bring there snowboard to a stop transverse of the slope and then sit down directly on the snow thus resulting in a high rate of heat transfer from the snow to the snow boarders body and creating a somewhat awkward maneuver as the snowboarder later endeavors to arise from the sitting position.
Referring to FIG. 6 , in one preferred embodiment the snowboarder has the option of, making a stop along the way and placing his or her hands gripping the handle down at his or her opposite sides to engage the skis 15 transversely of the slope incline and to then sit down on the transversely extending seats 35 for a comfortable rest with the buttocks supported in an elevated position above the snow somewhat insulated from the transfer of heat to snow surface. In that regard, the struts may have a length to support the handles 2″-3″ above the respective skis to provide space for entry of a gloved hand and to elevate the respective seats 35 above the snow.
Referring to FIG. 5 , in a second embodiment of the protective ski appliance of the present invention, the handle, generally designated 51 is connected directly to the top ski surface by means of holding screws 53 .
Referring to FIG. 7 , in a third embodiment the protective ski appliance incorporates a hand strap 57 which may be employed to wrap about the wrist of the snowboarder to allow the appliance to be suspended from the snowboarder's wrists.
Referring to FIG. 8 , the protective ski appliance of the present invention may incorporate the handle 21 connected directly to the ski 15 by means of struts 23 without the addition of the snowboarder seats 35 .
Referring to FIG. 9 , in some instances, the protective ski appliance of the present invention may be incorporated as the handle of a ski pole, generally designated 61 , having a basket 63 on the lower extremity thereof and formed to provide the benefits of allowing a skier to reach out on the downhill side during a fall to engage the ski 15 with the snow surface and to afford some degree of shock absorption and force dissipation in the event the shovel of the ski 15 happens to be pointed downhill to thus allow the body of the pole to be dragged along behind the ski.
From the foregoing, it will be appreciated that the protective ski appliance of the present invention provides economical, reliable and compact means for affording protection to a snowboarder or skier in the event of a fall during a decent down a ski run to thus minimize injury to the snowboarder and provide for a more safe and secure sporting experience. | A hand held protective ski appliance including a ski no longer than 18″ inches long and including a handle extensive with the direction of the ski and spaced therefrom about 3″ inches. | 0 |
This application claims priority to French Patent Application No. 01 10393 filed on Aug. 2, 2001, the entire contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to the field of aboveground pools and, more specifically, it relates to improvements made to above-ground pools which can be covered using a removable cover, the pool and the cover being provided with mutual fastening means distributed over their respective perimeters.
DESCRIPTION OF THE PRIOR ART
In the case of pools of generally round shape—a shape which is that of many models of above-ground pools, whatever the type—the absence of an angular region suitable for making it easy to start putting a cover in place requires the presence of two people, located one on either side of the pool, in order to unroll and fasten the cover.
Moreover, above-ground pools of the type called “self-supporting” are provided with an air-inflated chamber which forms the upper edge of the container and which, because of its buoyancy, tensions the flexible sidewall of the container filled with water. Now, apart from the fact that this type of pool is round and has the aforementioned drawback, the presence of the very rounded edge formed by the buoyancy chamber contributes to making the cover slide when starting to fit it onto the pool: for this reason too, the presence of two people proves to be useful, or even essential in order that the cover can be fitted and fastened over the pool.
SUMMARY OF THE INVENTION
The aim of the invention is to overcome the drawbacks which have just been mentioned and to provide an improved arrangement for the pool and for the cover which allows the cover to be placed and fastened over the pool by a single person and with a minimum number of manipulations, whatever the shape—even round—of the pool and even where the pool has a rounded upper edge which is not very useful at least for starting to fit the cover, said improved arrangement moreover having to be structurally as simple as possible and not to involve too great an additional cost.
To these ends, it is proposed a coverable above-ground pool as mentioned in the preamble, wherein, according to the invention:
the pool has an upper edge protruding radially outward from the immediately underlying sidewall,
first fastening means are provided on the cover folded in an arrangement for storage and in a first location on the perimeter of the pool, under said peripheral edge projecting therefrom, to allow the initial attachment of the cover to the pool,
second and third fastening means are provided in a second and a third location respectively, on the perimeter of the cover and on the perimeter of the pool, under the peripheral edge projecting there from, for the intermediate attachment of the cover, these second and third locations being located on either side of the mid-plane of the pool passing through said first location and being located such that a line joining them is located at not more than arm's length from a fourth location of the pool opposite said first location,
and lacing means are secured to the peripheral edge of the cover with tensioning means located at a fourth location on the perimeter of the cover located approximately on the opposite side from said first fastening location and corresponding with said fourth location of the pool, said tensioning means being suitable for allowing the lacing means engaged under the peripheral edge projecting from the pool to be tightened.
The arrangement according to the invention proves to be particularly beneficial because of the simplification in handling that it affords. This is because, once the folded cover has been attached to the pool at said first location thereof, this first attachment acts as an anchoring point for the cover over the pool: the user then has both hands free to unfold the cover and to start to open it out while following one of the sides of the pool until reaching the second fastening location where he attaches the pulled side of the cover. The user then passes to the other side of the pool where he grabs the other side of the cover which he can pull up to the third fastening location where he attaches the cover. It is then enough for him to pass to the fourth location, located on the side opposite the aforementioned first location, from which he can grab the remaining free edge of the cover and pull it toward him, in order finally to finish fastening it by using the means for tightening the lacing means (in practice, by gripping and tying the ends of the lacing cord) engaged under the projecting edge of the pool.
Thus, the cover may, according to the desired aim of the invention, be quickly put in place by a single person, quickly and without particular difficulty, with a smaller number of maneuvers (in principal four in the context of the procedure mentioned above).
Advantageously, the second and third fastening locations are located approximately symmetrically on either side of a line joining the first and fourth locations on the perimeter of the pool and of the cover.
In a preferred embodiment, the cover is secured to a bag suitable for containing it folded in a storage arrangement and the first fastening means are secured to said bag. Advantageously, the bag has at least one perforated region, located toward its bottom, for the water to flow out. Also in a desirable manner, the bag comprises closure means suitable for keeping it closed while the cover is unfolded over the pool, so as to prevent water (overflow from the pool, rain) falling into the empty gaping bag.
It is also desirable to make sure that the fastening means are simple and without movable pieces, on the one hand, in order to obtain as low a manufacturing cost as possible and, on the other hand, in order to simplify the putting on and taking off of the cover as much as possible. To this end, provision can be made for the fastening means to comprise, on the one hand, T-shaped fingers fastened to the pool or to the cover (or to the bag, respectively) and, on the other hand, eyelets suitable for accommodating said T-shaped fingers and provided on the cover (or on the bag, respectively) or on the pool. In the context of the arrangement of the preferred embodiment indicated above, the first fastening means may comprise at least one T-shaped finger provided on the storage bag at the first location of the folded cover and at least one corresponding eyelet provided at the first location on the perimeter of the pool and the second and third fastening means may comprise eyelets provided at the second and third locations of the respective cover and T-shaped fingers provided at the second and third locations of the perimeter of the pool.
In a beneficial particular application, the arrangements of the invention apply to self-supporting aboveground pools: in this case, the pool is defined peripherally by at least one inflatable flexible chamber and the means for fastening and the means for lacing the unfolded cover are located under this chamber.
Still with the aim of simplifying the task of a user working alone in taking off the cover, provision is made for the cover to have a region, which is permeable to liquids, in the form of a strip lying approximately in a direction joining the first and fourth fastening locations and extending over most of the distance separating said locations, for the purposes of allowing water deposited on the top of the cover used over the pool to pass through. In this case, it is possible to envisage in an advantageous manner that the cover further comprises two regions, which are permeable to liquids, which are located on either side of said region in the form of an elongated strip and over a transversal to the latter approximately in its middle and toward the periphery of the cover, in order to make it easier to remove water retained on the cover.
As already envisaged above, the arrangements of the invention are most particularly applicable to pools which have a periphery of continually concave curved general shape, in particular approximately round.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood on reading the following detailed description of certain embodiments given by way of non-limiting example. In this description, reference may be made to the appended drawings in which:
FIG. 1 is a perspective view of a pool equipped according to the invention so that it can be covered with a cover;
FIG. 2 is a perspective view of a preferred embodiment of a pool cover arranged according to the invention and shown in the folded state in a storage bag;
FIGS. 3 to 5 are perspective views respectively illustrating three steps of putting the cover of FIG. 2 in place over the pool of FIG. 1; and
FIGS. 6 and 7 are top views respectively illustrating two pools of different shapes, covered according to the invention with respective covers constituting preferred variants of the cover illustrated in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates, by way of example, a round aboveground pool 1 , of the self-supporting type, in which the flexible wall 2 is supported by an air-inflated peripheral chamber 3 which extends along the upper peripheral edge. Although the arrangements of the invention may be applied to many types of pool of various shapes and/or structures, it is in the case of a self-supporting pool such as the one illustrated that the invention seems to be due to find a preferred application because of its overall round shape and the overall toroidal shape of its upper edge which complicates putting a cover in place.
As is visible in FIG. 1, fastening means for a cover are placed on the outer face of the flexible wall 2 and immediately below the chamber 3 . These fastening means are discontinuous and distributed over the perimeter of the pool. All these means could be identical in order to cooperate with complimentary means, themselves mutually identical, provided on the cover. However, in order to facilitate putting on and taking off a cover by a single person, provision is made as follows.
At a first location P 1 of the pool (in principle located anywhere because of the round shape of the pool), there are first fastening means preferably of female type, that is to say in the form of an eyelet or the like. These first fastening means are intended for the first attachment of the cover and, in order to facilitate the work of the user operating alone, it is desirable that these first fastening means are in rigid form. It is for this reason that they may consist of a connecting block, or preferably, as illustrated, by two connecting blocks 4 fastened side by side on the flexible wall of the pool. These connecting blocks are hollow and they comprise, on their front face, an elongated opening 5 .
For its part, the cover 6 illustrated in FIG. 2, which is intended to be fastened to the pool 1 in order to cover and protect the latter, is, in the folded state for the storage arrangement, in the form of an overall parallelepipedal package held by any suitable means (webbing, strap). In a preferred manner, the folded cover is contained in a bag 7 which is secured to the cover. To prevent damage to the folded cover in the presence of water and moisture, it is desirable that the bag 7 has at least one perforated region, toward its bottom, for the water to flow out and, advantageously, an opening 8 , for example covered with mesh, in its upper part in order to ventilate its content.
On its back, the package formed by the folded cover or, in the example illustrated, the bag 7 comprises first first fastening means that are the complement of the aforementioned fastening means of the pool. As is visible in FIG. 2, the first fastening means provided on the bag 7 are in the form of one, or preferably two, T-shaped fingers 9 separated from each other. The transverse bar of the T of the two fingers 9 can be fitted into the connecting blocks 4 , the transverse bar of the T having, for this purpose, a length slightly greater than the length of the openings 5 so that once engaged in the connecting block 4 through the opening 5 , it cannot be released without suitable manipulation.
To put the cover in place, the user starts by attaching the folded cover, or the bag 7 in the preferred embodiment illustrated in FIG. 3, by fitting the fingers 9 of the bag in the connecting blocks 4 of the pool 1 .
The user then opens the bag 7 , unfolds the cover 6 and starts to open it out above the pool by first of all moving along one side of the pool (for example the right-hand side—arrow D) as illustrated in FIG. 4 . On this side, and at some distance from the first attachment means 4 , the pool 1 is provided, at a second location P 2 , with second fastening means which, for example, consist of a T-shaped finger 10 . For its part, the cover 6 is provided with corresponding second fastening means which, in the example in question, consist of an eyelet 11 which is suitable to fit onto said T-shaped finger 10 .
Once the cover 6 is therefore fastened on a first side, the user passes to the other side of the pool and pulls the cover 6 along this opposite side (arrow G in FIG. 4 ), until the third fastening means (for example an eyelet) of the cover are facing the third fastening means (for example a T-shaped finger) located at a third location P 3 of the pool. He assembles these fastening means such that the cover 6 is then unrolled and fastened over most of the pool.
Finally, the user positions himself approximately on the side opposite said first location and grasps the free end of the cover which he pulls toward him in order to completely cover the pool as shown in FIG. 5 (in this FIG. 5, the pool is shown from a different angle so that it is possible for said first location P 1 and the opposite location or fourth location P 4 to be seen simultaneously).
The cover 6 is provided with peripheral lacing means, in particular continuous means, as illustrated (but which could be discontinuous), consisting of a cord 12 which is engaged peripherally under the inflatable chamber 3 . Being located at said fourth location P 4 , the user tightens the lacing means using tensioning means: put simply, the two branches of the cord 12 are tightened and its free ends are tied, as shown in FIG. 5, such that the cover 6 is then firmly fastened under the chamber 3 over its entire periphery and can no longer be lifted even in the case of a gust of wind.
The pool 1 equipped with its cover 6 is shown, schematically in top view, in FIG. 6, and the first, second, third and fourth locations P 1 to P 4 , respectively, mentioned above, can be better identified therein.
The second and third locations P 2 and P 3 must be located such that the user located at the fourth location P 4 is able to grasp the free end of the cover previously attached to the locations P 2 and P 3 . In other words, since the locations P 2 and P 3 define a line L, the distance D from the fourth location P 4 to the line L should be at most equal to an arm's length, that is to say of the order of about 1 m.
By virtue of the arrangements of the invention, it is possible for a single user to put a cover in place over a pool in spite of the latter having a not very favorable structural shape, and it can be put in place with a limited number of manipulations (four in the example which has just been described).
Of course, additional fastening locations can be provided if that proves to be necessary or desirable, especially for large pools, it being however emphasized that the fastening locations are mainly provided to facilitate putting the cover on, although the cover is secured to the pool by the lacing means engaged under the projecting edge of the pool.
As indicated above, the provisions of the invention find a preferred application for pools of continually concave curved general shape and especially round pools. However, the invention may also be used for pools of different shapes. By way of example, FIG. 7 illustrates the implementation of the invention for a rectangular pool, said first location P 1 then advantageously being provided roughly in the middle of a short side and the second and third locations being located respectively on the two large sides near to the opposite short side.
Furthermore, the arrangements of the invention may be applied to above-ground pools with a structure different from that of a self-supporting above-ground pool. In particular, they could be applied to pools with a flexible “liner” wall supported by a rigid external frame provided that this pool has a peripheral upper rim which projects outward so that the lacing means can be engaged under this projecting rim.
Provision may advantageously be made, especially for the cover, for various arrangements to simplify its use.
With regard first of all to the bag 7 , it is noticed that, in the position for putting the cover 6 over the pool (FIGS. 4 and 5 ), the bag 7 hangs over the side of the pool. To prevent it hanging so that it gapes, thereby being filled with water should it rain for example, closure means (push buttons 13 , adhesive tape or hooks, etc.) are provided in order to keep it closed.
Moreover, in a manner known per se, it is desirable that rainwater does not stagnate on the tightened cover so that the latter is not weighed down with the risk of causing the fastening/lacing means to come off and also to facilitate its taking off. For this purpose, provision is made for the cover 6 to have a region 14 , which is permeable to liquids, in the form of a strip lying approximately in a direction joining the first and fourth locations P 1 , P 4 , as illustrated in FIGS. 6 and 7 , and extending over most of the distance separating said locations P 1 , P 4 .
Moreover, still for the purposes of facilitating the removal of water when taking the cover 6 off, it is possible to provide two regions 15 , which are permeable to liquids, which are located one on either side of said region 13 in the form of an elongated strip and over a transversal to the latter approximately in its middle and toward the periphery of the cover: especially in the diameter perpendicular to the diameter P 1 , P 4 if the pool is round (FIG. 6) or on the midline of the long sides if the pool is rectangular (FIG. 7 ). | An above-ground pool ( 1 ) having a protruding edge ( 3 ) and which can be covered with a cover ( 6 ): the folded cover, possibly enclosed in a bag ( 7 ) is anchored to a first location (P 1 ); next, it is unfolded and drawn over the pool successively on either side thereof and it is successively anchored at two points (P 2 , P 3 ) such that a line joining these two points is located at arm's length from a fourth point (P 4 ) on the opposite side from the first point (P 1 ); finally, it is drawn from the point (P 4 ) where the lacing means ( 12 ) passing peripherally under the edge ( 3 ) are tied. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application no. PCT/EP00/11699, filed Nov. 24, 2000, which claims the priority of both German application no. 199 62 393.7, filed Dec. 23, 1999 and application no. 199 56 669, filed Nov. 25, 1999, and each of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a soundproofing element. More particularly, the invention relates to a first sheet of flexible material, and a second sheet of flexible material; the first and second sheets being positioned at a distance from another and connected to each other at the surfaces facing one another by a connector; at least one chamber being formed between the first and second sheets for receiving a filler medium.
BACKGROUND OF THE INVENTION
[0003] Soundproofing elements, for instance in the form of soundproofing walls, are generally known, and serve as sound insulation, such as for the insulation of traffic noise, construction noise, or noise in factories.
[0004] Soundproofing elements are known from DE 30 04 102 C2 and DE 42 30 786 A1, that are essentially rigidly constructed. Although these soundproofing elements provide very effective soundproofing, their disadvantage, however, is that they are hard to handle due to their large weight.
[0005] A soundproofing element is known from DE 196 52 871 C2, that possess a first sheet consisting of flexible material, and a second sheet of flexible material, whereby the sheets are positioned at a distance from one another and at least one chamber is formed between the sheets for receiving a filler medium. In the known soundproofing element, the sheets are constructed in the form of a flexible jacket that can be inflated with air or other gases as the filler medium. One disadvantage of the known soundproofing element is that the sound insulating effect is low due to the gaseous filler medium.
[0006] A similar soundproofing element is also known by DE 44 22 585 C1.
[0007] A soundproofing material is known from DE 41 31 394 A1 that is essentially rigidly constructed, and possesses two cover layers, between which a core layer is positioned.
[0008] Furthermore, a soundproofing material is known from DE 40 40 583 A1 that consists of plastic hollow sections in which, or between which, wastewater sludge is placed.
[0009] A soundproofing mat is known from DE 83 09 535 U1 that possesses two layers of plastic foil, between which chambers are constructed for receiving a sound insulating work material.
[0010] A soundproofing element of the relevant type is known from the magazine Schweizer Ingenieur und Architekt [“Swiss Engineer and Architect,”] 38/1984, page 718, that possesses a first sheet consisting of flexible material, and a second sheet consisting of flexible material, whereby the sheets are positioned at a distance from one another, and whereby the first sheet and the second sheet are connected by connection means located on opposing surfaces. The sheets in the known soundproofing element are constructed of a spacer fabric, the spacer threads or the pole threads of which form the connecting means for the connection of the sheets to one another. The flexible soundproofing wall constructed in this way possesses excellent sound insulating characteristics. However, a disadvantage is that their production is complicated, and therefore expensive. Another disadvantage is that the known soundproofing element can be produced at only a short maximum width.
[0011] The invention further relates to a soundproofing wall of the type having a first soundproofing element, and at least a second soundproofing element.
[0012] Such a soundproofing wall is known from GB 2 305 451 A. It possesses a first soundproofing element, and at least a second soundproofing element, whereby the first soundproofing element and the second soundproofing element are arranged in neighboring proximity to each other, and whereby additional soundproofing means are intended that span an area in which the first and the second soundproofing elements are in neighboring proximity to each other, by soundproofing it. The additional soundproofing means on the soundproofing wall known from the specification are constructed of cover panels that are connected to a supporting pole of the soundproofing wall by means of screws or rivets. One disadvantage is that this construction is complicated in its production, and therefore expensive, and that the cover panel possesses only a low soundproofing effect.
[0013] Similar soundproofing walls are also known from DE 295 13 248 U1, DE 91 13 416.1 U1, DE 197 32 904 A1, and DE 86 12 223 U1.
[0014] The invention is based on the task of stating a soundproofing element and a soundproofing wall with simplified production methods, that is therefore constructed less expensive, and with which a high soundproofing effect can be achieved.
[0015] This task with regard to the soundproofing elements is solved by the inventive teaching of a first sheet of flexible material, and a second sheet of flexible material; the first and second sheets being positioned at a distance from one another and connected to each other at surfaces facing one another by a connector; at least one chamber being formed between the first and second sheets for receiving a filler medium; the connector possessing at least one connecting length including a flexible material; the connecting length being connected to the first sheet and the second sheet in such a way that a multitude of chambers is formed that are arranged next to each other; and the chambers being separate from each other, and each possessing a lockable fill opening for the filler medium that can be locked, and with regard to the soundproofing wall, by the inventive teaching feature of a soundproofing wall, with a first soundproofing element, and at least a second soundproofing element, whereby the first soundproofing element and the second soundproofing element are arranged in neighboring proximity to each other, and whereby additional soundproofing means are provided that span an area in which the first soundproofing element and the second soundproofing element neighbor each other, as sound insulation, the additional soundproofing means possess an additional soundproofing element according to one of the previous embodiments that can be connected to and detached from the first soundproofing element and the second soundproofing element. The soundproofing wall may be configured so that the additional soundproofing element is friction-lock connected to the first soundproofing element and/or the second soundproofing element.
[0016] The invention is based on the knowledge that an excellent soundproofing effect can be achieved by using a filler medium consisting of hard material of high density, such as sand, granulate, or similar.
[0017] Accordingly, the invention is based on the idea of connecting the first and the second sheets to one another in such a way that at least two chambers are formed, and an undesired deformation of the soundproofing element is prevented when filling with a filler medium consisting of hard material.
[0018] The inventive soundproofing element therefore enables the use of filler media consisting of hard materials that have a substantially higher density and therefore a substantially higher soundproofing effect, than gaseous media. The inventive soundproofing element therefore achieves an excellent soundproofing effect.
[0019] The inventive soundproofing element has a low weight in its unfilled state, and is therefore easy to handle. It can therefore be used in various applications, such as a mobile soundproofing element for temporary sound insulation, for instance in the area of construction sites.
[0020] After the soundproofing element has been set up, it is filled with the filler medium so that the desired soundproofing effect is achieved.
[0021] After use, the filler medium can be removed from the soundproofing element so that the same advantages with regard to easy handling exist in disassembling the soundproofing element, as in the set up.
[0022] A safe connection of the first sheet with the second sheet is achieved by means of the connecting length, whereby the weight of the soundproofing element is kept low by essentially omitting rigid connection elements, such as metal. The connecting length can consist of the same material as both the first and the second sheets. However, it may also consist of a different material.
[0023] An extremely advantageous further embodiment of the previously mentioned embodiment intends that the connecting length along side the width expansion of the first sheet and the second sheet, or along side the height expansion of the first sheet and the second sheet is successively connected to the first sheet and the second sheet. This results in an even connection along side the width expansion, or the height expansion, respectively, of the sheets, and therefore an even load of the soundproofing element by the filler medium in its filled state. Deformations caused by uneven loads or damages of the soundproofing element are safely avoided in this way.
[0024] Purposefully, the connecting length connects the first sheet with the second sheet in the cross section essentially in a zig-zag shape, or a meander shape in the previously mentioned embodiment. In this way, the evenness of the connection of the first sheet with the second sheet is further improved.
[0025] The connecting length can generally have any suitable form. For example, the connecting length can extend over a part of the width of the first sheet and/or the second sheet only so that both sheets are connected only across part of their width, which may be sufficient depending on the application. However, it is also possible to intend several connecting lengths in neighboring proximity to each other, or positioned at a distance from one another. Advantageously, however, the connecting length extends across a substantial part of the width of the first and/or the second sheet, preferably substantially across the entire width of the first sheet and/or the second sheet. In this embodiment, the first sheet is connected to the second sheet across a substantial part of the width, or the entire width, respectively, of the sheets. This results in a higher stability of the soundproofing element even when filled with filler media of higher density.
[0026] It is generally sufficient if the connecting length extends across a part of the height of the first sheet and/or the second sheet. The stability of the soundproofing element, however, can be further improved if the connecting length extends across a substantial part of the height of the first sheet and/or the second sheet, preferably substantially across the entire height of the first sheet and/or the second sheet, as it is intended in an additional further embodiment.
[0027] Purposefully, the connecting length is positioned at a distance from the first sheet and the second sheet from one another, preferably at essentially even distanced connection points to one another.
[0028] The connection points can have any suitable form, for instance, pointed. In an advantageous further embodiment the connection points are formed as lines or stripes, and are preferably parallel to each other. A lined or striped connection reliably avoids that the sheets are torn apart from one another, even with the filling with a filler medium of high density.
[0029] A further embodiment of the previously mentioned embodiment includes the lined or striped connection points being essentially vertical.
[0030] Another embodiment comprises the connecting length being connected to the first sheet and the second sheet in such a way that the chambers are open toward the top. In this embodiment, the filling of the soundproofing element with the filler medium is particularly easy. It is achieved by filling the filler medium into the chambers from the top.
[0031] In order to ensure an even distribution of the filler medium into the chambers, the chambers are separated from each other.
[0032] Purposefully, the fill openings, however, can be locked by locking means that are connected to, and specially formed onto the soundproofing element.
[0033] In the previously mentioned embodiment, the locking means can be configured in any suitable way. A further embodiment intends that the locking means possess at least one cap or latch consisting of flexible material, that can be fixed in its locking position. This embodiment is simple, and can therefore be cost-effectively produced.
[0034] A mutual cap or latch can be intended for the locking of at least one fill opening. The embodiment of the soundproofing element is further simplified in this way, and therefore even more cost-effective.
[0035] The cap or latch in the previously mentioned embodiment can be fixed in its locking position in any suitable way, for instance by snap fasteners or such. Advantageously, the cap or latch can be fixed in its locking position by means of a velcro fastener, as is intended in the embodiment. This eases the locking of the fill openings.
[0036] The filler medium can generally be removed through the fill opening, for instance, by pouring the contents out. Another advantageous further embodiment provides for at least one outlet opening for the filler medium that can be locked at a distance from the input opening. In this embodiment, the removal of the filler medium is made easier.
[0037] A mutual output opening can be intended for all chambers in the previously mentioned embodiment. Purposefully, however, one output opening for the filler medium that can be locked is intended for each chamber. The filler medium can separately be removed or discharged from each individual chamber in this embodiment.
[0038] According to each requirement, the locking means can be designed in any suitable way for the locking of the output openings. A particularly advantageous further embodiment intends that the, or each output opening can be locked by means of a screw cap. The discharging of the filler medium from the soundproofing element is further simplified in this way.
[0039] The flexible material of the first sheet and the second sheet, and the connecting length is selectable in broad ranges according to the individual requirements, whereby the sheets can consist of the same flexible material, or from different materials, such as plastic foil or sheets. According to a particularly advantageous further embodiment, the flexible material of the first sheet and/or the second sheet and/or the connecting length is a fabric, or knitted fabric. Damage to the sheets is avoided due to the fabric or knitted fabric structure, even when filled with filler media of high density, and with frequent use of the soundproofing element. The soundproofing element is especially robust and durable in this way.
[0040] It is generally sufficient if the flexible material is uncoated. The characteristics of the soundproofing element, however, can be further improved if the first sheet and/or the second sheet and/or the connecting length possess a one-sided or two-sided coating.
[0041] The coating in the previously named embodiment may possess a layer of PVC, as is intended in another further embodiment. The flammability of the soundproofing element is inhibited by the PCV layer. Further, the thermal stability and the UV stability are improved.
[0042] In addition to, or instead of the PVC layer, the coating may also possess a layer of a flame resistant material, as is intended in another embodiment. This further improves flame protection.
[0043] Purposefully, the coating possesses a varnish coat so that the surface of the soundproofing element is scratch and dirt resistant. Also, this hinders the deposit of dirt and micro-organisms in the sheets. In order to embodiment the soundproofing element optically more attractive, the varnish coat can be printed, for instance with a marketing print. Any varnishes may be used, such as acrylates and fluor polymer systems. Another advantage of the varnish coat is that the weather resistance of the soundproofing element is improved.
[0044] The connecting length can be connected with the first sheet and the second sheet in many different ways according to the respective requirements, such as by means of positive riveting. Purposefully, the connecting length, however, is welded or glued to the first sheet and the second sheet. This simplifies the production of the inventive soundproofing element.
[0045] With proper sealing of the chamber, or of each chamber of the soundproofing element, a gaseous or fluid medium can be used as the filler medium. Purposefully, the filler medium, however, is a pourable medium. In this way, the filling of the soundproofing element is easy, and an evaporation or leaking of the filler medium is reliably avoided. Especially preferred is a filler medium of high density, which results in a particularly well sound insulating effect.
[0046] The filler medium can be for instance sand, granulate, or similar, as is intended in another embodiment. It can also be a mixture of different filler media, such as sand with crushed scrap.
[0047] With a respective embodiment of the soundproofing element, and use of a suitable filler medium, the inventive soundproofing element can be designed self-supporting. Particular with the use of filler media of high density, however, it is advantageous that a support construction for the support of the soundproofing element is intended. In this way, large-scale soundproofing elements can be realized even with the use of such filler media.
[0048] The support construction of the previously named embodiment can be embodimented in many different ways according to the respective requirements, such as in a frame-type embodiment. A further embodiment intends that the support construction possesses two side supports positioned at a distance to one another. In this type of embodiment, the soundproofing element is attached on the side, thereby resulting in a stable construction.
[0049] The stability can be further improved if the support construction possesses a crossbeam that connects the side supports with each other.
[0050] The soundproofing element in the previously named embodiments can be attached to the side supports, or to the crossbeam, respectively, in any suitable way, such as by means of hooking them to hooks by means of eyelets, which are attached to the supports, or the crossbeam, respectively. A particularly advantageous embodiment intends that the soundproofing element is connected to the side supports and/or the crossbeam by means of a piping/groove connection. This achieves a form fit between the soundproofing element and the support construction so that the soundproofing element is particularly safely supported.
[0051] An extremely advantageous further embodiment of the inventive teaching intends a tension means for tensing of the soundproofing element. This type of embodiment achieves a particularly even distribution of the filler medium due to the tension effect of the tension means, and the risk of undesired deformations of the soundproofing element during filling is further reduced.
[0052] The soundproofing element in the previously mentioned embodiment can be tensed in vertical and/or horizontal direction by the tension means.
[0053] According to another embodiment, the tension means possess a first part for retaining the soundproofing element at an edge, and a second part for holding the soundproofing element at an edge positioned opposite of the tension direction, whereby the first part and the second part can be adjusted relative to one another for tensing the soundproofing element, and can be fixed in their respective adjusted position. This embodiment is simple in its construction, and can therefore be cost-effectively produced.
[0054] A further embodiment of the previously named embodiment intends that the first part is a retaining component that retains the soundproofing element locally fixed at its lower edge, and that the second part is constructed of the cross beam that is adjustable in the tension direction relative to the retaining component, and which retains the soundproofing element at its upper edge. The tensing of the soundproofing element in this embodiment occurs by adjustment of the crossbeam in vertical direction relative to the retaining component.
[0055] The adjustment of the crossbeam relative to the retaining component can occur in any suitable way. An advantageous embodiment intends that the respective crossbeam is connected to the side supports by means of a screwing device, particularly by an adjustable screw or a spindle, and can be adjusted relative to the retaining component by means of the screwing devices. This embodiment is constructed simply and robustly.
[0056] According to another further embodiment of the inventive teaching, the soundproofing element possesses a sealing element at its lower edge that surrounds and seals the soundproofing element from the bottom. The sealing element reliably prevents moisture from entering the sheets so that the weather resistance of the soundproofing element is further improved.
[0057] The sealing element is preferably constructed in the crossbeam in a U-shape, whereby the sealing element is purposefully constructed of a tarp or foil, which is connected to the soundproofing element preferably by gluing or welding. This embodiment is particularly simple, and therefore cost-effectively produced.
[0058] However, the sealing element can also be constructed with a coating, as is intended in another embodiment.
[0059] The shape and size of the inventive soundproofing element are selectable in additional ranges. The soundproofing element can, for instance, be bent or curved in any way, for example, it can be constructed in circular or half-circular shape in the cross section. It can also be constructed as a soundproofing housing, and completely surround a sound source. For this purpose, the soundproofing element can be constructed, for example, in a cube shape or a dome shape. However, one embodiment intends that the soundproofing element is constructed essentially evenly. In order to insulate a sound source, several inventive soundproofing elements can be grouped next to each other around the sound source in this embodiment, and form a soundproofing wall in this way.
[0060] Another further embodiment of the inventive teaching additionally intends that in addition to the first and the second sheets, at least one other sheet is provided, and that the additional sheet is positioned at a distance to the neighboring first or second sheet, and connected to it by connecting means. This results in a multi-shell construction by which the sound insulating effect is further improved. The connecting means can be designed as the connecting means for the connection of the first sheet with the second sheet.
[0061] In order to improve the sound insulating effect of the soundproofing element in an area in which the soundproofing element contacts the floor, a purposeful further embodiment intends at least one pocket-shaped receiver for a filler medium, or greenery that is arranged in front of the soundproofing element in an area in which the soundproofing element forms a contact to the floor with its lower edge.
[0062] Purposefully, the pocket-shaped receiver is constructed with an opening at the top, and/or consists of a flexible material, as intended in further embodiments.
[0063] In order to further improve the sound insulating effect by means of the pocket-shaped receiver, a further embodiment intends that a pocket-shaped receiver each is provided in front of both sides of the soundproofing element, whereby the receivers are connected to one another, and essentially positively surround the soundproofing element at its lower edge.
[0064] Advantageous and purposeful further embodiments of the inventive soundproofing wall may include:
[0065] the additional soundproofing element is connected to the first soundproofing element and/or the second soundproofing element by means of at least one velcro closure;
[0066] the additional soundproofing element is connected to the first soundproofing element and the second soundproofing element by clamping means;
[0067] the additional soundproofing element is arranged on the side of the soundproofing wall facing the sound source;
[0068] the soundproofing element includes:
[0069] a) a first sheet of flexible material, and a second sheet of flexible material;
[0070] b) the first and second sheets being positioned at a distance from one another and connected to each other at the surfaces facing one another by a connector;
[0071] c) at least one chamber being formed between the first and second sheets for receiving a filler medium;
[0072] d) the connector possessing at least one connecting length including a flexible material;
[0073] e) the connecting length being connected to the first sheet and the second sheet in such a way that a multitude of chambers is formed that are arranged next to each other; and
[0074] f) the chambers being separate from each other, and each possessing a lockable fill opening for the filler medium that can be locked.
[0075] the fill openings can be locked by locking means that are connected, particularly attached to the soundproofing element.
[0076] The invention is further explained in the attached, strongly schematic illustration, which includes an example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0077] It shows:
[0078] [0078]FIG. 1 a section of an inventive soundproofing element in schematic perspective view consisting of a first sheet and a second sheet that are positioned at a distance from one another and are connected to each other by means of a connecting length;
[0079] [0079]FIG. 2 a schematic front view of the soundproofing element according to FIG. 1 that is retained by means of a support construction;
[0080] [0080]FIG. 3 a schematic section along a line III-III in FIG. 2;
[0081] [0081]FIG. 4 a single unit of one of the side supports with the crossbeam of the support construction in the area of the connection in schematic perspective view;
[0082] [0082]FIG. 5 a horizontal section in a strongly schematic illustration through a soundproofing wall consisting of inventive soundproofing elements that are arranged in neighboring proximity to one another, whereby additional soundproofing means are constructed of an additional soundproofing element; and
[0083] [0083]FIG. 6 a vertical section in a strongly schematic illustration through an additional example of an inventive soundproofing element with the additional soundproofing means being constructed of pocket-shaped receivers.
DETAILED DESCRIPTION OF THE INVENTION
[0084] [0084]FIG. 1 shows a soundproofing element possessing a first sheet 4 , and a second sheet 6 consisting of a flexible material, which are positioned at a distance from one another and are connected to each other at surfaces facing each other by connecting means, which are constructed of a connecting sheet 8 consisting of flexible material in this embodiment.
[0085] In this embodiment, the flexible material of the sheets 4 , 6 , 8 consists of a polyester fabric that possesses a two-sided coating. The coating possesses a layer of PVC which inhibits flammability and improves the thermal stability and UV stability of the sheets 4 , 6 , 8 . The surface of the coating possesses a varnish layer consisting of a fluor polymer, which makes the surface of the soundproofing element 2 scratch and dirt resistant, and which prevents a deposit of dirt and microorganisms. The surfaces of the sheets 4 , 6 facing away from one another may have a print.
[0086] Alongside of the width expansion of the first sheet and of the second sheet, i.e., in FIG. 1 in the direction of the arrow 10 , the connecting length 8 is successively connected with the first sheet 4 and the second sheet 6 in such a way that the connecting length 8 connects the first sheet 4 with the second sheet 6 essentially in a zig-zag, or meander shape. The connection of the connecting length 8 with the first sheet 4 and the second sheet 6 is achieved by welding of stripe-shaped, essentially vertically running connection points, of which only one connection point is referenced by the number 12 in the drawing.
[0087] The zig-zag, or meander shaped connection of the connecting length 8 of the first sheet 4 and the second sheet 6 forms a multitude of chambers of essentially the same volume, that are arranged next to each other, and are open at the top, of which only two chambers with the reference numbers 14 , 16 are shown in the drawing, which can be filled with the filler medium at the fill openings 18 , 20 attached at their upper ends. The filler medium in this embodiment is sand, which results in a particularly good sound insulating effect.
[0088] As the drawing does not clearly show it, it is explained in further detail here that the connecting length 8 expands essentially across the entire height, i.e., in the direction of the arrow 22 in FIG. 1, as well as essentially across the entire width, i.e., in direction of the arrow 10 in FIG. 1, of the first sheet 4 and the second sheet 6 . In this way, an essentially even connection of the sheets 4 , 6 is achieved across the entire height and the entire width of the first sheet 4 and the second sheet 6 . The soundproofing element 2 , that is flexibly designed in the embodiment, therefore possesses a high stability so that damages of the connecting points 12 are reliably prevented with the filling of filler media even of high density. Furthermore, this results in an even distribution of the filler medium in the soundproofing element 2 in its filled state.
[0089] [0089]FIG. 2 shows a front view of the soundproofing element 2 possessing a support construction in this embodiment that consists of two side supports 24 , 26 , and a crossbeam 28 , which connects the supports 24 , 26 with each other. Additionally, the support construction in this embodiment possesses a retaining component 30 that is firmly connected to the side supports 24 , 26 , and that locally retains the soundproofing element 2 at its lower edge 32 . The crossbeam 28 retains the soundproofing element 2 at its upper edge, and is vertically adjustable relative to the retaining component 30 in the direction of the double arrow 36 as explained in detail in FIG. 4, and can be fixed in its respective adjustment in a way further explained by FIG. 4, and thereby forms a tension means for tensing the sheets 4 , 6 , 8 that are connected to each other.
[0090] The soundproofing element 2 possesses piping flanges 38 , 40 , 42 at its sides and at its upper edge that positively engage in complementary formed grooves in the supports 24 , 26 , or the crossbeam 28 so that the soundproofing element 2 is safely connected to the support construction via a piping/groove connection.
[0091] As FIG. 2 shows, the stripe-shaped connection points 12 extend essentially across the entire height of the sheets 4 , 6 in such a way that the connecting length 8 connects the sheets 4 , 6 essentially across the entire height of the sheets 4 , 6 .
[0092] The soundproofing element 2 possesses a locking means in the area of the fill openings 18 , 20 , which is constructed of a flap 46 that can be folded out that is connected to the second sheet 6 , and is attached at its upper edge 44 , and as shown in FIG. 2 can be folded out from the drawing level, which closes the fill openings facing the viewer in FIG. 2 of the chambers 14 , 16 positioned next to each other, as well as the additional chambers. In the locking positioned illustrated in FIG. 2, the flap 46 can be attached to the second sheet 6 by means of a not illustrated velcro closure.
[0093] In the area of their lower ends, the chambers possess outlet openings for the filler medium, that can be locked by means of screw caps in this embodiment, of which only one screw cap in FIG. 2 is referenced with the number 48 .
[0094] [0094]FIG. 3 shows a section across a line III-III in FIG. 2. It shows that the piping flanges 38 , 40 of the sheets 4 , 6 , 8 that are connected to each other, engage into complementary formed grooves 48 , 50 of the side supports 24 , 26 . The side supports 24 , 26 in this embodiment are constructed of full profile components. However, they may also be constructed of hollow profile components.
[0095] [0095]FIG. 3 also shows that the connecting length extends essentially across the entire width of the sheets 4 , 6 , and connects them in a zig-zag, or meander shape to each other. The chambers facing away from the viewer in FIG. 2, such as chamber 14 , also possess outlet openings that are locked by means of screw caps, of which only one screw cap is referenced with the number 52 in FIG. 3.
[0096] [0096]FIG. 2 shows a perspective illustration of a singularity in the area of the connection of the crossbeam 28 with the side support 24 . The support 24 possesses a U-shaped pin 56 that is attached to the support 24 by means of push bolts 58 , 60 . The crossbeam 28 is received between the legs of the U-shaped pin 56 at its free end, and adjustably connected with the support 24 in vertical direction by means of a set screw 60 .
[0097] The functionality of the inventive soundproofing element 2 is as follows:
[0098] The soundproofing element 2 possesses a low weight in its empty state so that it can be easily transport and handled. The soundproofing element 2 is respectively positioned in the area of the sound source for insulating the sound. Then the chambers 14 , 16 , as well as the additional chambers, are filled with sand as the filler medium by means of the assigned fill openings 18 , 20 . In order to avoid a gathering of the filler medium in the lower area of the chambers, the soundproofing element is first tensed by means of a vertical adjustment of the crossbeam 28 in vertical direction. In this way, a “sagging” of the sand, and an undesired gathering in the lower area of the chambers 14 , 16 is avoided. By way of the even distribution of the sand in the chambers 14 , 16 achieved in this way, an essentially even sound insulating effect is achieved across the entire surface of the essentially evenly constructed soundproofing element 2 . Additionally, this results in an even load on the connecting points 12 so that a damage of the soundproofing element 2 is avoided in these areas.
[0099] After the filling of the chambers 14 , 16 , and the additional chambers with sand, the fill openings 18 , 20 , and the additional fill openings are locked by means of the flap 46 , and the flap 46 is fixed in its locking position by means of velcro closures. This reliably avoids penetration of moisture into the chambers 14 , 16 .
[0100] The inventive soundproofing element 2 exhibits a particularly good sound insulating effect owing to the filler medium of high density.
[0101] After use of the soundproofing element 2 , the sand can be discharged by opening the screw caps 48 , 54 , and the additional screw caps. The soundproofing element 2 can again be easily handled and transported away.
[0102] [0102]FIG. 5 shows a horizontal section across a soundproofing wall, generally identified by 100 , which consists of the soundproofing element 2 according to FIGS. 1 to 4 , as well as an additional soundproofing element 102 . The soundproofing element 102 is constructed as has been described in FIGS. 1 - 4 for the soundproofing element 2 . The soundproofing elements 2 , 102 are arranged in neighboring proximity, and bordering each other, whereby the soundproofing element 102 possesses sheets 104 , 106 , 108 that are connected to each other, which are retained at their sides facing the soundproofing element 2 at the support 26 , and at their sides facing away from the soundproofing element 2 at a support 126 .
[0103] The soundproofing elements 2 , 102 possess connection means in the areas of their edges for the connection with additional soundproofing means, which are constructed of an additional soundproofing element 202 in this embodiment. The additional soundproofing element 202 is constructed in a corresponding way to the soundproofing elements 2 , 102 , and possesses sheets 204 , 206 that are connected to each other by a connecting length 208 . The chambers formed in the soundproofing elements 2 , 102 , and the additional soundproofing element 202 are filled with a filler medium when the soundproofing wall 100 is in use, such as with water.
[0104] The connection means for the connection of the soundproofing elements 2 , 102 with the additional soundproofing element 202 are constructed with VELCRO® (e.g., hook-and-loop fastener) closures in this embodiment, which are arranged at 210 , 212 . By means of the velcro closures, that run across the entire height of the soundproofing elements 2 , 102 , the additional soundproofing element 202 can be connected to the soundproofing elements 2 , 102 by friction-locked and detachable closure. It extends across the entire height of the soundproofing elements 2 , 102 , and, as FIG. 5 shows, completely spans across the area in which the soundproofing elements 2 , 102 are neighboring each other. This avoids the formation of a sound bridge in the area of the support 26 so that the soundproofing wall 100 as a whole possesses a high insulating effect.
[0105] In a corresponding way, additional VELCRO® (e.g., hook-and-loop fastener) closure components 214 , 216 can be arranged in the area of the edges of the soundproofing elements 2 , 102 , in order to further increase the soundproofing wall 100 by adding additional soundproofing elements, and in order to add additional soundproofing means to those areas in which neighboring soundproofing elements are arranged respectively, such as in the form of additional soundproofing elements 202 .
[0106] [0106]FIG. 6 shows a vertical section across an additional embodiment of an inventive soundproofing element 2 . In this embodiment, the additional soundproofing means are constructed of two pocket-shaped receivers 218 , 220 that are open at the top, that are intended for holding greenery 222 , 224 . The pocket-shaped receivers 218 , 220 are connected to one another by means of a material length 226 , and essentially positively surround the soundproofing element 2 at its lower edge, as illustrated in FIG. 6. In this way, the additional soundproofing elements formed by the pocket-shaped receivers 218 , 220 reach into an area in which the soundproofing element 2 contacts the floor at its lower edge. This avoids the formation of a sound bridge in this area, and improves the sound insulating effect.
[0107] While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto. | Soundproofing element includes a first sheet including a flexible material and a second sheet consisting of flexible material. The sheets are positioned at a distance from one another and at least two chambers are formed between said sheets for receiving a filler medium. The first sheet and the second sheet are connected by connection element located on opposing surfaces. Appropriately, the connection elements have at least one connecting length consisting of flexible material. The soundproofing element is constructed simply and robustly. When empty, it is easy to handle and transport. In addition, the inventive soundproofing element is suitable for filling with a high-density filler medium, for example sand or similar material. | 4 |
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Provisional Application No. 60/286,937, filed on Apr. 27, 2001.
FIELD OF THE INVENTION
[0002] This invention relates generally to control systems for automobile power convertible tops and power windows, and more particularly to a method of controlling an automobile power convertible top and power windows.
BACKGROUND
[0003] In the field of automotive design, convertible tops are used to provide automobiles that are capable of being driven with the top down or the top up. The drivers and passengers of convertible top automobiles often prefer to drive the vehicle with the top down when the weather outside is pleasant and place the top up when the weather turns foul or cold. Occupants of the vehicle also frequently put the automobile windows in the same position as the convertible top. That is, when the top is down, the occupants prefer to also have the windows down and vice-versa.
[0004] Typically, convertible tops are mechanically coupled to an electric motor that raises and lowers the convertible top in response to a command from an operator. The command is usually given through a power top switch conveniently located in the passenger compartment of the automobile, such as on the dash or center console. Similarly, typical power window arrangements are driven by electric motors that raise and lower the windows in response to commands from power window switches.
[0005] On vehicles having both a power convertible top and power windows, it is desirable to provide a control system that lowers the convertible top and windows with a single push of a button instead of the separate power top and window switches mentioned above. It is further desirable to provide a control system that protects the components of the convertible top structure and moving mechanism from damage due to excessive drive forces of the power top motor in the event the top structure becomes jammed while moving. Known control systems monitor the movement or position of the convertible top and turn off power to the electric motor when the top is completely raised, lowered, or becomes jammed. Such control systems require a feedback path that provides the control system with instantaneous information related to the positions of the structure members of the convertible top. These feedback paths require hardware that adds cost to the convertible top assembly, increases complexity in the assembly process, and requires maintenance.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method and apparatus for controlling the raising and lowering of an automobile body member, such as a convertible top or power window.
[0007] One aspect of the invention is to provide a convertible top control system that is integral to a power window control system, where the combined control system has the capability of raising and lowering the convertible top and power windows in response to a single operator input or switch actuation.
[0008] Another aspect of the invention is to provide a convertible top control system that raises and lowers the top in response to a single operator input, where the control system operates without need for a feedback path.
[0009] In accordance with these aspects, a method of controlling a movable body portion of a vehicle is provided where the body portion is moved by a motor that responds to a control input. The method applies power to the motor upon actuation of the control input and maintains a timer concurrent with the application of power. Power is removed from the motor upon the earliest occurrence of either the expiration of the timer or the relinquishment of the control input. The timer provides a maximum amount of time that power may be applied to the motor, thereby preventing damage to the convertible top in the event it becomes jammed while it is being moved by the motor.
[0010] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes 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 DRAWINGS
[0011] [0011]FIG. 1 is a block diagram illustrating a convertible top control system;
[0012] [0012]FIG. 2 is a state diagram illustrating a method of controlling a convertible top and power windows, and;
[0013] [0013]FIG. 3 is an X-Y plot illustrating a predetermined time vs. battery voltage relationship.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Turning now to FIG. 1, a convertible top control system 10 is shown. The control system 10 is centered around a body controller module (BCM) 30 that executes a method 200 shown in FIG. 2 and explained later. The BCM monitors a power top switch assembly 20 that is used by an operator to indicate whether the top should be stopped, raised, lowered, or simultaneously lowered with the windows (express down). Switch assembly 20 is an example of such an assembly that is implemented in a resistive-multiplexed (R-mux) configuration. While the R-mux switch is discussed in more detail below, such a switch arrangement is not be construed as limiting.
[0015] R-mux switch assembly 20 is referenced to ground 28 and has an output connected to an analog-to-digital converter (A/D) pin 44 of the BCM 30 . The A/D pin 44 of the BCM 30 is pulled-up to a reference voltage (+V ref ) as is well known in the art. An operator presses switch 22 to indicate a top up state, and presses switch 24 to indicate a top-down state. Pressing switch 24 past a certain point causes switch 26 to close concurrently with switch 24 , thereby indicating a top and windows down state. All of the switches 22 , 24 , and 26 are normally open. When neither switch 22 nor switch 24 is pressed, pin 44 is at a first voltage level. Pressing switch 22 causes a voltage level corresponding to a top-up command to appear at pin 44 . Pressing switch 24 causes a voltage level corresponding to a top-down command to appear at pin 44 , and pressing switch 24 even further, thereby causing switch 26 to close, effects yet another voltage level at pin 44 corresponding to the top and windows down state.
[0016] In accordance with the method 200 , the BCM 30 responds to the power top switch 20 by activating one or more of the top up relay 50 , the top down relay 40 and relays of the window relay box 60 . The output contacts of the top up relay 50 and top down relay 40 are electrically connected across a power top motor 70 . The output shaft of the power top motor 70 is mechanically connected to the convertible top (not shown) so that rotating the power top motor 70 in one direction causes the convertible top to move in a top up direction. Similarly, rotating the power top motor 70 in the opposite direction causes the convertible top to move in a top down direction and, finally, stopping the power top motor 70 causes the convertible top to stop moving. The power top motor 70 is preferably electrically protected by a top circuit breaker 120 .
[0017] As mentioned earlier, the BCM 30 is also electrically connected to a window relay box 60 . Actuating the window relay box 60 causes all window motors 80 to roll down the vehicle windows. The window relay box 60 contains a relay for each power window motor 80 . The relays inside of the window relay box 60 are electrically connected to the power window motors 80 in such a way that the relays are able to effect downward movement of the power windows by controlling electrical power to the power window motors 80 . Each power window motor 80 is preferably protected by a window circuit breaker 110 connected in series with the power window motor 80 . The system 10 also includes power window switches 90 electrically connected to the power window motors 80 to allow control of the power windows independent of the BCM 30 and window relay box 60 . Electrical power for the convertible top control system 10 is supplied by the vehicle electrical system, symbolized by the battery 100 .
[0018] [0018]FIG. 2 shows the control process executed by the BCM 30 . At power up, the method starts in state 210 and proceeds to state 220 where it reads the power top switch 20 . Upon detection that the power top switch 20 is in any of the top up, top down or top and window-down positions, the method proceeds to state 230 and determines whether the timer 32 has expired. The timer 32 keeps track of the amount of time that the power top motor 70 has been running in response to actuation of switch 20 .
[0019] Turning briefly to FIG. 3, a graph is shown indicating how the expiration time of the timer 32 is determined. The x-axis 190 of the graph represents the system voltage 100 , and the y-axis 180 represents expiration time. Curve 170 represents the maximum amount of time that it should take for the power top motor 70 to raise the convertible top at a given system voltage 100 . Similarly, curve 150 represents the maximum amount of time that it should take for the power top motor 70 to lower the convertible top at a given system voltage. Curve 160 represents the maximum amount of time that it should take for the power top motor 70 to lower the convertible top when the power windows motors 80 are simultaneously started with the power top motor 70 (express down). The method 200 allows the power top motor 70 to run for no longer than the predetermined amount of time from these curves to complete the desired operation. By limiting the amount of time the motor may run, the method 200 protects the components of the convertible top structure from being damaged by the drive forces of the power top motor 70 in the event the structure is jammed. The actual shape and relative positions of the curves 150 , 160 , and 170 will vary depending on physical parameters such as the torque of the motors, the length and gauge of wires used in the system 10 , etc. In addition to choosing the time values to correspond to the maximum amount time it should take for the power top motor 70 to complete an operation, the time is also preferably less than the time it takes for the circuit breaker 120 to open when the convertible top is jammed. This allows an operator to clear the jammed top and resume operation of the system 10 without having to wait for the circuit breaker 120 to reset. Both requirements should be satisfied over a range of system voltages to produce a locus of points such as those shown in FIG. 3.
[0020] Returning to state 230 in FIG. 2, if timer 32 has expired then the method proceeds to state 350 where the method shows that it has determined to turn off the power top motor 70 . The method then proceeds to state 340 where the BCM 30 actually turns off the power top motor 70 and resets the timer 32 before returning to state 220 .
[0021] Returning to state 230 , if the timer 32 has not expired, then the method proceeds to state 240 where it checks whether a predetermined condition has been met. In one aspect of the invention, the predetermined condition is that the vehicle must be travelling at a speed less than fifteen miles per hour. If the predetermined condition in state 240 is not satisfied then the method proceeds to state 350 and executes the aforementioned 110 sequence of states from 350 to 340 to 220 , thereby turning off the power top motor 70 , resetting the timer 32 , and returning to read the power top switch 20 .
[0022] If, instead, the predetermined condition in state 240 is satisfied, the method proceeds in accordance with the switch position determined in state 220 . More specifically, if the method determined the power top switch 20 is in the top up position then the method advances from state 240 to state 270 . In state 270 the method acknowledges the top up request before moving to state 320 . In state 320 , the method updates the timer 32 for a first duration of time 170 and activates the top-up 50 and top down 40 relays in such a manner as to cause power top motor 70 to effect raising of the convertible top. From state 320 the method returns to state 220 where the power top switch 20 is checked once again.
[0023] Returning to state 240 , if the method determined the power top switch 20 is in the top down position then the method advances from state 240 to state 280 . In state 280 the method acknowledges the top down request before moving to state 300 . In state 300 the method maintains a the timer 32 for a second duration of time 150 and activates the top-up 50 and top down 40 relays in such a manner as to cause power top motor 70 to effect lowering of the convertible top. From state 300 the method returns to state 220 where the power top switch 20 is checked once again.
[0024] Returning to state 240 , if the method determined the power top switch 20 is in the express down position, then the method advances from state 240 to state 250 . In state 250 , the method acknowledges the express down request before moving to state 260 . In state 260 , the method maintains the timer 32 for a third duration of time 160 and simultaneously activates the top-up relay 50 , top down relay 40 , and the window relay box 60 . This simultaneous activation causes the power top motor 70 to effect lowering of the convertible top concurrently with the lowering of the power windows by window motors 80 .
[0025] In each of states 300 , 320 , and 260 , the method maintains the timer 32 by initiating the timer on the first entry into the state, and updating the timer value on each entry thereafter. The timer 32 is reset in state 340 when method turns off the power top motor 70 .
[0026] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A method and system of controlling a movable body portion of a vehicle where the body portion is moved by a motor responding to a control input. Power is applied to the motor upon actuation of the control input and a timer is maintained concurrent with the application of power. Power is removed from the motor as a function of expiration of the timer or relinquishment of the control input. The timer provides a maximum amount of time that power may be applied to the motor, thereby preventing damage to the movable body portion in the event it becomes jammed while being moved by the motor. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a trap for crawling insects and the like and more particularly to such a trap which is adapted to isolate objects to be protected, such as potted plants, bird feeders and food goods, from attack by crawling insects, spiders and the like which are attracted to such objects.
2. Description of the Prior Art
The susceptibility of plant life, food goods, camping supplies, fish bait, game and other organic materials to attack by insects, spiders and other surface borne creatures is frequently considerable depending upon how they are used and stored. This susceptibility results from the capability of such creatures to crawl up vertical surfaces, along the undersides of horizontal structures and into confined spaces. These capabilities coupled with their instinct for locating food substances has made the protection of such materials extremely difficult. Thus, for example, it is known in camping to suspend containers of food from tree limbs in an attempt to isolate such containers from crawling insects and animals. However, insects are frequently able to locate and gain access to such containers notwithstanding their isolated locations. Similarly, with other objects such as hanging potted plants and bird feeders, this same difficulty exists. The prior art, such as represented by the Scribner U.S. Pat. No. 1,063,395; the Lindecker U.S. Pat. No. 2,051,800; the Wright U.S. Pat. No. 2,356,022; and the Du Mond et al. U.S. Pat. No. 3,441,003, disclose prior art devices which deal with peripherally related problems not directly applicable to the problem here presented.
Therefore, it has long been known that it would be desirable to have a device which can be employed to support objects so as to preclude access thereto by surface borne insects, spiders and the like and which is of a compact, durable construction suitable for use in a wide variety of environments throughout a long operational life.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved trap for surface borne insects, spiders and the like.
Another object is to provide such a trap which is adapted to support a variety of types of objects, such as containers of food, potted plants, bird feeders, camping supplies, fish bait, game and the like which are attractive to, and subject to damage by, crawling insects and the like, so as to preclude access thereto by such crawling creatures thereby preserving such objects from damage.
Another object is to provide such a trap which employs a fluid barrier impassable to crawling creatures.
Another object is to provide such a trap which can be constructed in a variety of operative embodiments particularly well suited to specific uses.
Another object is to provide such a trap which is of a durable construction adapted to support even relatively heavy objects while itself being compact and lightweight.
Another object is to provide such a trap which is particularly well suited in camping to the preservation of food, supplies and the like permitting the support of such materials on an available means of support, such as a tree limb, and which is of lightweight construction and permits disassembly for compact storage thus enhancing its portability.
Another object is to provide such a trap which can easily be manufactured and sold in a variety of embodiments at minimal cost.
Another object is to provide such a trap which has an aesthetically pleasing appearance so as not to detract from the ornamental effect afforded by objects such as potted plants supported thereon.
Further objects and advantages are to provide improved elements and arrangements thereof in an apparatus for the purposes described which is dependable, economical, durable and fully effective in accomplishing its intended purposes.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation of the trap of the present invention shown in a representative operative environment with a bird feeder and a food container alternatively represented in dashed lines as supported thereon.
FIG. 2 is a somewhat enlarged perspective view of the trap showing fluid retained therein.
FIG. 3 is a somewhat further enlarged top plan view of the trap.
FIG. 4 is an exploded view of the trap.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing, the trap of the present invention is generally indicated by the numeral 10. The trap is shown in a representative operative environment in FIG. 1, wherein a suitable support 11, such as a beam, tree limb or the like is shown in dashed lines and mounts an eye fastener 12. It will be recognized that a variety of fasteners could be employed in place of the eye fastener including simply a line lashed about a support. For illustrative convenience, a bird feeder is represented in dashed lines at 13 supported on the trap. The feeder typifies loads that can be supported on, and protected by, the trap. Food containers, potted plants, and other objects not shown similarly benefit by being supported on the trap.
As will be seen, the trap 10 of the present invention can be constructed in a variety of embodiments individually designed for particular uses. However, the embodiment of the invention shown in the drawing and described herein is well suited to virtually all uses and is therefore the preferred embodiment.
The trap 10 has a cup-shaped container or receptacle 25. The receptacle can, of course, be constructed of any suitable material such as metal, plastic, or the like. However, it is preferably constructed of a rigid transparent plastic material for purposes subsequently to be described. The receptacle has a substantially flat floor 26 having an interior surface 27 and an exterior surface 28. The floor has a central bore 29 extending substantially axially therethrough and a substantially circular peripheral edge 30.
The receptacle 25 has an inverted frustoconical side wall 35 integrally mounted on the peripheral edge 30 of the floor 26 extending continuously thereabout. The side wall has an interior surface 36 and an exterior surface 37. The side wall, with the floor, defines a fluid reservoir 38 within the receptacle. The side wall has an upper edge 39 defining a mouth 40 for the receptacle communicating with the reservoir.
An elongated body member 50, having opposite ends 51 is mounted on and extends substantially axially through the receptacle 25. The body has a cylindrical sleeve 52 mounted on the interior surface 27 of the floor 26 and extending in substantially coaxial relation concentrically about the central bore 29. The sleeve has an internal passage 53 and a remote end 54 which extends beyond the upper edge 39 of the side wall 35. The sleeve is preferably mounted on the floor in fluid sealing relation as by means of a suitable adhesive or actually molded as an integral part of the receptacle.
The body 50 is further composed of a bolt 60 having an externally screw-threaded end portion 61, a central flange 62 and a fastener or hook 63. The bolt is extended through a seal 64, through the central bore 29, the internal passage 53 of the sleeve 52 and outwardly through the remote end 54 of the sleeve. A washer 65 is positioned about the screw-threaded end portion of the bolt and a nut 66 is screw-threadably received on the end portion 61 and tightened into engagement with the washer thereby to force the washer into engagement with the remote end 54 of the sleeve. The bolt is thus secured in position with the hook 63 extending outwardly from the exterior surface 28 of the floor 26. The seal 64 acts to cushion engagement of the flange 62 with the floor and insure a fluid-tight seal. An internally screw-threaded fastener or hook 67 is screw-threadably secured on the outwardly extending end portion 61 of the bolt 60 and tightened into engagement with the nut 66. Thus, the body member 60 is provided with opposite ends 51 individually mounting the hooks 63 and 67 respectively. As shown for illustrative convenience in FIGS. 1 and 2, a fluid 68 is contained within the reservoir 38 of the receptacle 25. The fluid may, of course, be an insecticide in liquid or powder form, but for purposes of safety and convenience water is normally preferred and is found to be quite adequate.
As previously discussed, the embodiment shown in the drawing and described herein is preferred due to its versatility of use. However, it is important to note that other embodiments of the invention may be more desirable for specific applications of use. For example, in camping where food containers 15 are to be suspended thereon, and where light weight and compact storage are desired, such as where supplies are transported by back pack, another embodiment of the invention, not shown in the drawing, may be preferred. Thus, the receptacle 25 can be constructed in a cup shape as shown in the drawing but without the central bore and elongated body structure 50 heretofore described. A suitable fastener, such as an eyelet, can be mounted on each surface 27 and 28 respectively of the floor 26. Thereupon, a cord, rope, chain or the like can individually be extended through the eyelets for attachment to the support 11 and for attachment to the tie line 16 for the food container 15. This construction permits the cords to be removed from their eyelets and a plurality of such receptacles 25 to be disposed in nested relation with respect to each other for ease of storage.
OPERATION
The operation of the described embodiment of the subject invention is believed to be clearly apparent and is briefly summarized at this point. As heretofore set forth, the trap 10 of the present invention can be used in a variety of environments for the support of objects to be protected from surface borne insects, spiders and other crawling creatures. As illustrated in FIG. 1, fluid 68 is simply placed in the reservoir 38 of the receptacle 25 and the hook 67 is inserted through the eye fastener 12 so as to support the trap in depending relation on the support 11. Thereafter, the object to be protected, such as the bird feeder 13, is simply suspended on hook 63.
If crawling insects, spiders or the like are able to reach the support 11, the fluid 68 received in the reservoir 35 acts as a barrier thereby preventing them from passing to the hook 63 and the object supported thereon. In the case of objects such as potted plants, bird feeders, or the like which are to be retained in the suspended position virtually indefinitely, the only maintenance required is to replenish the supply of fluid 68 within the reservoir which may be lost due to evaporation or spilling. In such usage, the transparency of the receptacle, as described, facilitates observation of the fluid level. In the preferred form of the invention shown in the drawing and described herein, the interlocking assembly of the bolt 60 with the hook 67 so as to capture the receptacle securely therebetween permits the trap to support the maximum amount of weight while minimizing the weight, complexity of structure and thus expense of the trap itself.
Therefore, the trap of the present invention is adapted dependably and securely to support a wide variety of types of objects so as to protect them from attack by surface borne creatures, such as insects, spiders and the like, and is of compact, durable and lightweight construction facilitating use and insuring a long operational life.
Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the illustrative details disclosed. | A trap having a receptacle forming a fluid receiving reservoir with a mouth communicating therewith, a fastener attached to the receptacle and extending substantially centrally through the reservoir and mouth for attaching the receptacle to a support in depending relation with the mouth disposed in substantially upwardly facing relation, and a second fastener borne by the receptacle for supporting an object to be protected in depending relation thereon. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method and a device for printing with error or fault correction. More particularly, it relates to a print head for an ink-jet printing system having an error or fault correction device, and to a method of correcting errors or faults when printing with an ink-jet printing system.
[0003] In ink-jet printing systems, tiny droplets of ink are produced by one or more print heads and are applied to a printing material. In order to produce the droplets of ink, the print head is formed with a multiplicity of nozzle openings, each of which is connected to a respective pump mechanism. Pump chambers of the pump mechanism are filled with printing ink, and a device is provided by which positive or excess pressure can be produced briefly in the pump chamber. Due to the positive pressure, a small quantity, respectively, of printing ink is displaced and escapes via the nozzle opening. By a linear configuration of a multiplicity of nozzles for the same color, it is possible to print a large region of a page and an entire page, respectively, with a printing ink. If different inks, for example cyan, magenta, yellow and black, are then disposed after one another, it is possible to produce over an entire page a colored print resulting from the overprinting of a color separation for each printing ink. In practice, however, it has repeatedly been shown that, during the operation of the print heads, individual nozzles can fail and, thereby, a respective colored point or location is missing on the printing material. These missing print points can be detected by the eye and, to some extent, considerably disrupt the printed image.
[0004] In order to monitor the nozzle for the serviceability thereof, and to correct nozzles that have failed, it has been proposed, for example in U.S. Pat. No. 6,270,187, to monitor the serviceability of the individual nozzles continuously. As long as no fault results from this monitoring, the printing material would be printed in accordance with the stipulations. However, if it is detected that one of the nozzles has failed, it is proposed that all the nozzles in the row of colors which lie between the nonfunctioning nozzle and the end of the rows of nozzles be switched off. The task of the nozzles which have been switched off is then taken over by the other nozzles which are still functioning. In the most undesirable case, however, when a nozzle lying in the center of the row of nozzles should fail, only half of the row of nozzles can still be used, and therefore the printing speed is reduced considerably. As an alternative thereto, it is proposed that the printed point of the failed nozzle be set by an adjacent nozzle element, or that a substitute row of nozzles be provided, which is always then applied when a nozzle element fails.
[0005] In U.S. Pat. No. 5,581,284, it is proposed that, upon the failure of a nozzle, the colored point of the nonfunctioning nozzle be replaced by a colored point of a different color. Although this method can avoid excessively high visibility of the failure of a single nozzle as a result of a colored point not being set on the printing material, the disadvantage is that this method necessitates another, highly differing color (for example magenta) being set instead of the correct color (for example cyan). This type of correction is also visible to the human eye, in particular when a contribution to a colored line or colored area is to be printed with the failed nozzle.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a method and a device for printing with error or fault correction, which overcome the hereinafore-mentioned disadvantages of the heretofore-known methods and devices of this general type and which provide a print head having a correction mechanism, and a method of correcting a print in the event of failure of a nozzle, wherein the correction is barely visible to the eye and the printing speed is simultaneously maintained.
[0007] With the foregoing and other objects in view, there is provided, in accordance with the invention, a printing device for an ink-jet printing system, comprising at least one row of nozzles for overprinting a first process color, and a row of nozzles for overprinting a correction color. The correction color is different from the process color.
[0008] In accordance with another feature of the invention, in addition to the one row of nozzles for overprinting the first process color, further rows of nozzles for overprinting further process colors are provided. The process colors overprintable by the first and the further rows of nozzles are cyan, magenta, yellow and black.
[0009] In accordance with a further feature of the invention, the printing device further includes a device for monitoring serviceability of the nozzles for overprinting the colors.
[0010] In accordance with an added feature of the invention, the device for monitoring serviceability is a device for monitoring voltage variation when controlling the nozzles for overprinting the colors.
[0011] In accordance with an additional feature of the invention, the printing device further includes an inspection system disposed between the rows of nozzles for overprinting the process colors, on the one hand, and the row of nozzles for overprinting the correction color, on the other hand, for monitoring the printed image applied by the process colors.
[0012] In accordance with yet another feature of the invention, the printing device further includes a device for controlling each individual nozzle of the row of correction nozzles when a malfunction of the nozzles for overprinting the process colors is detected.
[0013] In accordance with yet a further feature of the invention, the printing device further includes an inspection system disposed between the rows of nozzles for overprinting the process colors, on the one hand, and the row of nozzles for overprinting the correction color, on the other hand, for monitoring the printed image applied by the process colors. The device for controlling the individual correction nozzles is automatically activatable upon detection by the inspection device of a malfunction of the process nozzles.
[0014] In accordance with yet an added feature of the invention, the device for controlling the individual correction nozzles is automatically activatable upon detection of a malfunction of the process nozzles.
[0015] In accordance with yet an additional feature of the invention, the nozzle-controlling device serves for manually activating the individual nozzles of the row of correction nozzles.
[0016] In accordance with still another feature of the invention, the correction nozzles are connected to a color reservoir having a correction color formed of a weighted sum of the process colors.
[0017] In accordance with still a further feature of the invention, the correction color is a gray tone.
[0018] With the objects of the invention in view, there is also provided a method of correcting failure of a nozzle for overprinting a process color in a print head of an ink-jet nozzle system having a plurality of rows of nozzles, to each of which a respective process color is assigned. The method comprises detecting a failure of a nozzle for overprinting one of the process colors, and depositing a correction color different from the color of each of the process colors at a fault location on the printing material, which is caused by the failure of the nozzle.
[0019] In accordance with another mode, the method of the invention further includes monitoring each individual nozzle for overprinting the process colors for detecting the failure of the nozzle for one of the process colors.
[0020] In accordance with a further mode, the method of the invention further includes detecting the nozzle failure by an optical inspection system for monitoring the printed image applied to the printing material.
[0021] In accordance with an added mode, the method of the invention further includes activating a nozzle from a row of nozzles of a correction head for applying the correction color.
[0022] In accordance with an additional mode, the method of the invention further includes forming the applied correction color of a weighted mixture of the process colors being used.
[0023] In accordance with a concomitant mode, the method of the invention further includes forming the applied correction color as a gray tone.
[0024] According to the invention, in order to correct the failure of a nozzle in a print head, the point or location at which a nozzle has failed is thus occupied by a correction color. As a result of the use of a row of nozzles for overprinting a correction color, a row of nozzles is thus available for the entire width of the print head, and by the aid of the row of nozzles, each individual nozzle of the print head can be corrected. Since the correction color is different from each of the process colors which are used, the correction color can be used for any of the process colors being used. The corrected printing image will certainly not correspond exactly to the originally intended printed image, but it is possible to correct the printed image in such a way that the failure of the nozzle cannot be detected or can be detected only with difficulty.
[0025] The process colors cyan, magenta, yellow and black are normally used in one or more print heads. The correction color that is selected is therefore advantageously a gray, which results from a suitable percentage mixture ratio of the indicated process colors. In order to detect whether a correction nozzle must be activated, in principle all those methods are available by the aid of which it is possible to detect whether one of the nozzles of the process colors has failed. In particular, each individual nozzle of the process colors can be monitored for serviceability thereof during the overprinting. When it is detected that a nozzle has failed, the corresponding correction nozzle of the correction head can be activated.
[0026] As an alternative thereto, it is also possible to monitor the printed image applied with the aid of the process colors. This is normally done with the aid of a scanner, which is disposed to follow the process color nozzles. The scanner registers the printed image applied by the process print heads and compares it with a desired or nominal printed image. If differences result from this desired-actual comparison and permit a conclusion to be drawn regarding the failure of an individual nozzle in one of the process colors, then the corresponding correction nozzle is activated and the correction color is introduced into the fault location. With the use of the correction head according to the invention, it is therefore possible in the ink-jet method to correct the failure of an individual nozzle regardless of the type of process color.
[0027] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0028] Although the invention is illustrated and described herein as embodied in a method and a device for printing with fault or error correction, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0029] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a diagrammatic, side-elevational view of a print head according to the invention;
[0031] [0031]FIG. 2 is a diagrammatic, plan view of FIG. 1; and
[0032] [0032]FIG. 3 is a view similar to that of FIG. 1 of a schematically and diagrammatically illustrated alternative correction head configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a first embodiment of a correction head according to the invention. In this case, a paper sheet 10 is moved into a paper conveying device represented by the arrow A. The printed image to be applied to the paper sheet 10 is applied with the aid of different process colors. In this regard, different respective print heads 12 , 14 , 16 , and 18 containing the various process colors are normally used. The print head 12 contains the process color cyan, the print head 14 the process color magenta, the print head 16 the process color yellow and the print head 18 the process color black. In this regard, one must take into account that, for one, other process colors can also be used and, for another, more or less of the specified process color print heads 12 , 14 , 16 and 18 can be used, because this depends only upon the desired printed image. Provided downstream of the last process color print head 18 is a registration device 20 for registering the printed image which has been applied to the paper sheet 10 . In this regard, an optical inspection device, such as a scanner, in particular, can be used. The registration device 20 registers the printed image applied to the paper sheet 10 . By comparing this printed image with a stored nominal or desired printed image which, for example, can be provided in a non-illustrated computing unit, a determination is made as to whether one and more, respectively, of the nozzles of the process color heads 12 , 14 , 16 or 18 , have failed. If this is the case, a correction head 22 is controllingly driven so that the failure of this nozzle and these nozzles, respectively, is compensated for by the activation of corresponding nozzles of the correction head 22 . In this regard, a corrective printing ink is applied to the faulty or error location in the printed image.
[0034] This procedure may be clarified once more by reference to the plan view of FIG. 2. The paper sheet 10 moves in the conveying direction represented by the arrow A and is led appropriately past the process color print heads 12 , 14 , 16 and 18 . Each of these process color print heads is equipped with nozzles 24 . The nozzles are located adjacent one another within each print head in the illustrated embodiment, i.e., they are disposed in respective rows. It is accordingly possible to apply the applicable process colors, respectively, line-by-line to the paper sheet. However, in order to fit the nozzles within the print head, other configurations are also considered if, as a result, for example the density of the colored points which is to be placed on the paper sheet 10 can be increased. Thus, in each or one process color print head of a color, the nozzles can also be disposed in two rows, in particular offset in relation to one another in the rows. With the aid of the registration device 20 , following the application of all the process colors to the paper sheet, the printed image applied to the paper sheet is monitored and then examined to see whether a nozzle 24 in one of the process color print heads 12 , 14 , 16 , 18 has failed. If this is established with the aid of an electronic evaluation of the results obtained via the registration device 20 , a correction head 22 disposed downstream of the process color print heads 12 , 14 , 16 , 18 in the conveying direction of the paper sheet, which is represented by the arrow A, is activated, so that this fault can be compensated for. In this regard, a correction color is applied to the paper sheet.
[0035] For example, as a result of a failure of the nozzle 26 in the process color print head 12 , the line 28 will not be printed on the paper sheet. This is detected via the registration device 20 . The correction nozzle 30 corresponding to the nozzle 26 and belonging to the correction head 22 is then activated, and the line 28 , which is erroneously not occupied by process printing ink, is occupied by the correction color 30 , if appropriate in accordance with the pattern to be applied.
[0036] In FIG. 3 a further embodiment of the invention is shown, wherein the device according to the invention basically manages without the registration device 20 . Again, the paper sheet 10 is moved in the conveying direction of the arrow A relative to process color print heads 12 , 14 , 16 and 18 in order to provide the paper sheet with printing ink. Each of the process color print heads 12 , 14 , 16 and 18 is connected to a monitoring device 32 , which monitors the correct function of all the nozzles 24 of the process color print heads 12 , 14 , 16 and 18 . Upon a determination that one of the nozzles 24 of the process color print heads has failed, the correction nozzle head 22 is activated either via the monitoring device 32 or via a non-illustrated monitoring device to be provided separately and, as described hereinbefore, a correction color is applied in order to compensate for the failed or omitted process color.
[0037] Before the activation of the correction head 22 , a check can moreover be made to determine whether the failed nozzle of the process color print head is actually to be corrected with a correction printing ink. In this case, it is possible in particular to take into account whether the failed process color together with the background or the color of the paper sheet 10 makes any correction necessary. For example, it is possible to dispense with a correction by the correction head 22 when the failed process color is yellow and the surface of the paper sheet is white. In addition, it is possible, before using the correction print head, to set different threshold values, the correction head being activated only when these threshold values are exceeded. This can be advantageous in particular when only individual points are overprinted in only specific regions and cannot readily be perceived by the eye even without any correction by the correction head 22 . If desired, a further correction head can also be provided, which is fitted with a correction color that is different from the correction color of the first correction head 22 .
[0038] If the simplest possible structure is required, then it is also possible to dispense with the automatic activation of the correction nozzle and/or the automatic detection of a failed process nozzle. The printed image then has to be checked manually for the failure of a process nozzle by the operating personnel, and the correction nozzle correspondingly activated manually. For this purpose, an activation facility, for example a switch or a possible software intervention, then has to be provided. | A printing device for an ink-jet printing system includes at least one row of nozzles for overprinting a first process color, and a row of nozzles for overprinting a correction color. The correction color is different from the process color. A method of correcting failure of a nozzle in a print head of an ink-jet nozzle system is also provided. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a grinder brewer device for the grinding of coffee beans and distribution of the ground coffee to a brew basket for brewing of a coffee beverage.
Typical coffee grinding apparatus having the capability of grinding coffee beans and delivery of the resulting ground coffee either to a bag or, in the case of a combination grinder-brewer apparatus, to a brew basket employing some type of bag or basket holding device to hold the bag or basket beneath a channel communicating with the grinder. It has long been known to provide some fail-safe mechanism to prevent operation of the grinder in a grinder apparatus for the delivery of grounds to a bag. For example, U.S. Pat. No. 2,900,140 to Schulman et al discloses a coffee grinder that uses a contact switch that prevents operation of the grinder unless a bag is positioned beneath the grinder and further requires the operator to manually move a lever to a grinding position. U.S. Pat. 4,685,624 to Nidiffer discloses the use of a mechanically operated rocker arm that closes a normally open switch in the grinder circuit when the arm is engaged by a bag put into position beneath the grinder opening.
The industry lacks a combination coffee grinder-brewer in which the grinder and/or brewer mechanism will not operate unless the brewer basket is in position between the retaining arms for the basket. Moreover, such combination apparatus do not have the ability to make ground coffee without the brewing operation being initiated. Therefore, it is an paramount object of the present invention to provide for a combination grinding and brewing apparatus in which a grind only feature is included. It is still another important object of the present invention to provide for a combination grinding and brewing apparatus in which the apparatus is disabled from carrying out any grinding and/or brewing cycles unless the brew basket is properly positioned in the apparatus.
SUMMARY OF THE PRESENT INVENTION
The present invention pertains to an apparatus having a coffee bean grinding system that has a cycle for the grinding of coffee beans and a cycle for the transfer of hot water to a brew basket in which the ground coffee is delivered or other ground coffee or flavored beverage substance is manually placed. The apparatus includes a grinder for grinding coffee beans and distributing the ground coffee into a brew basket held by a pair of pivotally mounted retaining arms. The basket is held by the arms beneath a passageway communicating with the grinder. The apparatus further includes a brewing system for the distribution of hot water over ground coffee positioned in the brew basket and a control circuit for initiating the grind-only, the brew-only, and/or the combined grinding and brewing cycles. The control circuit additionally has a brew basket sensing switch that is positioned adjacent the retaining arms and is open when no basket is positioned between the retaining arms and closed when a basket is positioned between the arms. The open brew basket sensing switch disables the control circuit which then does not initiate any cycle. Thus the problem of grounds or hot water being delivered accidentally when no basket is present is avoided.
DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective of a grinder and brewer apparatus incorporating the present invention;
FIG. 2 is a side view of the apparatus of FIG. 1 illustrating the various major components thereof;
FIGS. 3, 4 and 5 are schematic side views of the apparatus showing the vertical articulation of the arms of a brew basket retainer as a brew basket is being inserted between the arms;
FIG. 6 is a bottom view of the articulating arms of the grinder and brewer apparatus before insertion of a basket therebetween showing the positioning switch in contact with one of the arms and in a circuit open position and illustrating the pivoting action of the arms about a supporting structure;
FIG. 7 is a view identical to FIG. 6 except a brew basket is in position between the articulating arms showing the brew basket positioning switch out of contact with one of the brewing arms and in a circuit closed position;
FIG. 8 is a front view of the supporting structure for the articulating arms showing the pivoting action of the support structure about a horizontal axis;
FIG. 9 is a side view of the arms and supporting structure positioned within and cooperatively engaged to the housing of the apparatus;
FIG. 10 is a schematic showing the basic circuitry of the apparatus controller that includes brew basket sensing, grin-only, brew-only, grind and brew, and start cycle switches; and
FIG. 11 is a flow diagram illustrating the operative steps taken by an apparatus incorporating the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIGS. 1 and 2 in conjunction with FIG. 10 that illustrate an apparatus 10 for the grinding of coffee beans and the brewing of the resulting ground coffee. Apparatus 10 is provided with a water storage tank 12 that is connected via a siphon cup 13 and water line 14 to a water distribution head 17 positioned in apparatus 10 above a brew basket 18. Water from an outside remote source (not shown) is fed to tank 12 by water line 20 through off-on valve 22 and water pressure regulator 24. A hot water tap 21 fed by line 23 from tank 12 may be secured to the front of apparatus 10 as best seen in FIG. 2. A coffee bean storage hopper 26 communicates via funnel 27 directly to a coffee bean grinder 30 driven by a motor 32 or to an intermediate positioned bean portioning device such as solenoid operated slide valves or an auger mechanism 28 driven by an auger motor 29. The portioning device then feeds the predetermined volume of coffee beans to grinder 30. Because both of these portioning transfer mechanisms are well known in the prior art and not a part of the present invention, no discussion is deemed necessary. However, U.S. Pat. Nos. 4,789,106 and 5,217,108, respectively, illustrate valve and auger transfer devices that may be utilized with the present invention.
Following portioning of the beans by the portioning mechanism, grinder 30 receives and grinds the portioned beans with the resulting ground coffee being fed through grinder throat 34 into brew basket 18 maintained in position by a pair of articulating basket arms 16 (seen in FIG. 1). A decanter 38 is positioned beneath brew basket 18 on a hot plate 40.
As best seen in FIG. 1, the front wall of apparatus 10 supports a control panel that includes a brew only switch 90, grind only switch 92, grind and brew switch 94, full brew switch 96 and a half brew switch 98. The control panel also has a hot water ready indicator light 100, a basket out indicator light 102 and a cycle start switch 104. All of these will be discussed in more detail below.
When the basket 18 is positioned beneath and in an abutting relationship with underneath surface 10a, it is highly desirable that the arms 16 be able to accommodate different diameter and flange sizes of brew baskets. Commonly assigned and copending application Serial Number (Attorney's docket number 0001/205) describes a coffee grinder and brewer with arms that articulate vertically and horizontally and provide an advantageous assembly for receiving various style baskets. The details of such an assembly are described in the aforementioned application, with only the basic structure described herein for an understanding of the present invention.
As basket 18 is pushed between the arms 16, the arms are forced apart and are simultaneously moved downward. The latter motion is best seen in FIGS. 3, 4 and 5 while the former motion is depicted in FIGS. 6 and 7. As basket 18 engages the initial or front part 16a of the arms 16, a camming action occurs and arms 16 pivot downwardly away from surface 10a. Once basket 18 is completely pushed into place between arms 16, the upward biassing force of the arms 16 cause the flange 18a of basket 18 to engage the underneath surface 10a in a sealed relationship to prevent the escape of steam occurring during the brewing cycle. As stated in the aforementioned application, the arms are capable of accepting baskets of various diameters and flange widths.
Simultaneously with the vertical pivoting motion of arms 16, the arms are capable of pivoting about a vertical axis for motion in a horizontal plane. This is clearly seen in FIGS. 6 and 7 in which arms 16 are shown pivotally mounted about pins 52 journaled into an arm support brackets 50. From a comparison of FIG. 6 to FIG. 7, it is clear that arms 16 readily articulate horizontally apart to accommodate basket 18. Arms 16 are biased toward one another under the influence of a spring 54 attached at the distal ends thereof to flanges 56 integral with each arm 16. The ends of bracket 50 abut arms 16 when in the closed position illustrated in FIG. 6. As may be seen the opposite end or rear extension of each arm 16 is inwardly canted and provided with a gear element 58 that operably engage or mesh with one another. The operative engagement of the gear elements 58 ensure that the front portions of arms 16 move apart simultaneously along the identical arc segment about pin 52 and thus ensure that basket 18 is centered beneath surface 10a.
The structure permitting arms 16 to articulate vertically can best be seen in FIGS. 6, 7, 8 and 9. As seen therein, bracket 50 has a pair of right angle flanges 60 each spaced slightly from pins 52. Extending outwardly from each flange 60 is a pivot pin 64 with a cap 62 of greater diameter than the diameter of the shank of pivot pin 64. A helical torsion spring 66 is wrapped about a portion of the shank of each pivot pin 64. Each spring 66 is provided with a downwardly extending first leg 68 with outwardly turned distal ends 68a and, as described below, adapted to be secured to the side of the housing of the apparatus 10. A second leg 70 of each spring 66 is bent around and secured to its associated flange 60.
The entire brewer basket arm support assembly is mounted so that the shanks of pivot pins 64 ride on a pair of vertical slots (not shown) in the sides 74 of the apparatus 10 with the caps 62 abutting the outside surface of sides 74. The outwardly turned distal ends 68a are positioned within registering apertures 76 in sides 74. Thus, when a basket is urged between arms 16, the width of the basket flange causes arms 16 to be cammed downwardly against the biasing force supplied by springs 66. Once the basket is positioned within and firmly grasped by arms 16 due to the inward urging of spring 54, the upward force supplied by springs 66 causes the flange or rim 18a of basket 18 to tightly abut around the entire circumference thereof against the under surface 10a of apparatus 10. The abutment between flange 18a and surface 10a minimizes escape of moisture when a brewing cycle is underway and hot water is being distributed to the ground coffee.
As illustrated in FIGS. 6 and 7, bracket 50 actually extends beneath springs 54 with the opposite edges 54a and 54b serving as stops for arms 16 when in the closed position. In FIG. 8, it may be seen that bracket 50 has an upwardly and downwardly extending flange 78. The upper extension 78a of flange 78 serves as a guard for spring 54 while the lower extension 78b provides a mount for switch 82 (not shown in FIG. 8). As seen in FIGS. 6 and 7, switch 82 has a button 84 positioned to contact and be depressed by one of the arms 16 when in the closed position. When the arms are in the closed position, switch 82, as discussed below, is open and prevents energization of the apparatus for grinding and/or brewing cycle. Thus, unless a basket is in place between arms 16, the grind and brew cycle or grind-only cycle cannot be initiated.
The control circuitry and logic for the present invention is illustrated in FIGS. 10 and 11. A controller 86, for example, a programmable microprocessor, is connected to solenoid operated water valve 22, the circuitry and structure of the hot water transfer system as shown by numeral 15 and the connected water sensing probes 89a-c, hot water temperature sensor 91, hot water tap 21, brew-only switch 90, grind-only switch 92, hot water heating coils 93, grind and brew switch 94, full pot switch 96 and half pot switch 98. Additionally, controller 86 is in communication with auger portioning motor 29 and grinder motor 32. Initially, the unit is connected to a power source and valve 22 is opened until tank 12 is filled to water to a prescribed level as sensed by one of the water sensing probes 89. Controller 86 then turns on heating coils 93 until the temperature of the water reaches a predetermined level as measured by sensor 91. At this point, the indicator light 100 is turned on to indicate apparatus 10 is ready to operate. Coils 93 are periodically activated and deactivated depending upon the measurement made by sensor 91.
When indicator light 100 is on, the operator has available a number of operating modes each initiated by pushing one of the available switches 90, 92, or 94 on the front face of apparatus 10. A first mode includes the selection of a brew-only cycle in which ground coffee of a preselected type or some other flavorant can be manually placed into the brew basket and hot water is delivered to and distributed over the ground coffee or flavorant. A second mode includes the selection of a grind-only cycle in which only a grinding cycle occurs and ground coffee is delivered to the brew basket which then may be removed for use elsewhere. A third mode involves the combination of grinding and brewing cycles in which a precise throw of ground coffee is distributed into the brew basket followed by the distribution of hot water over the grounds. Additionally, the operator can also select either a full grind/brew or a partial grind/brew, e.g., a half grind/brew, for each operating mode. For example, when a half grind/brew pot is selected, then the selection of a grind-only operating mode would result in the delivery of a partial amount of ground coffee to the brew basket. A timing circuit may be used as part of the control circuit to control the duration of operation of the coffee bean portioning mechanism and thus the volume of beans delivered to the grinder. Similarly, the selection of the brew-only mode would result in a lesser amount of hot water being delivered to the basket using either volumetric or timing circuits as part of the control circuit. Although the description herein describes the use of separate switches for the full and partial pots for grinding and brewing, it should be understood that a full pot default mechanism may be provided necessitating only the closing of a partial pot switch when less than a full grind and/or brew is desired.
There are numerous types of well known hot water delivery systems in the prior art of coffee brewing including the volumetric system described in detail by U.S. Pat. 5,195,422 showing the use of water sensitive probes to provide selected different volumes of hot water to a brew basket. While it should be understood that other and different hot water transfer systems, such as timing hot water transfer systems, may be used in conjunction with the present invention, for the sake of simplicity, the system described generally herein and referred to in FIG. 10 is the one set forth in great detail in the aforementioned patent, incorporated by way of reference herein. At start up, the water rises within tank 12 until it touches sensor 89c. At this point controller 86 closes valve 22 in response to a signal from sensor 89c. When a brew cycle is initiated, valve 22 is again opened and the water is introduced at the bottom of tank 12, causing the water to again rise until it touches one of the sensors 89a (representing a full brew) or 89b (representing a partial brew). The valving structure of the volumetric system, shown generally as a box with character numeral 15, is activated and the water flows through siphon cup 13 to distribution head 17 until the level in the tank 12 recedes below the level of cup 13 and the suction thereto is broken. Reference is made to the aforementioned patent for the details of operation of water sensitive probes 89a, 89b, and 89c and the precise circuitry and structure of the hot water transfer system.
The flow chart of FIG. 11 clearly depicts the operative sequences of the present invention. Initially, the apparatus 10 is connected to an external power source and is turned on as indicated by ON circle 106. At this point, the operator is able to make decisions at block 108 and thereafter the start switch 104 is pushed to place apparatus in the START mode 110. Controller 86, as indicated by BOX 112, then determines which grinding/brewing size was selected and sets timers for the operating time of portioner mechanism and/or determines which water sensing probe is to be connected into the hot water transfer system. That is, when a half grind/brew and a grinding-only cycle have been selected, the portioner operates for a time necessary to carry a volume of coffee beans approximately one-half of a full amount to the grinder and the grinder motor then times out a predetermined time interval following the cessation of operation of the portioning device to ensure all beans delivered to the grinder have been fully ground and dispensed to the brew basket. Similarly, if a brewing-only cycle has been selected following the selection of a half grind/brew, the volume of hot water transferred to the brew basket is about one half of the amount transferred when a full grind/brew cycle has been selected. The full grind/brew cycle is indicated by BOX 114 and the half grind/brew is indicated by BOX 116.
However, none of the cycles can be initiated unless controller 86 has determined the brew basket is in position between the basket arms, as shown by BOX 118. If the determination is NO, then the basket must be put in before the cycles can be started. If the determination is YES, then controller 86 determines which operation mode has been selected and initiates the proper cycles, as illustrated by BOXES 122-128. The cycles then end at END CYCLE 130.
From a reading of the above, it may be seen that the grinding and brewing apparatus of the present invention provides considerable flexibility to an operator. By providing a grind-only feature, operators of the apparatus can use the device to grind coffee beans and manually transfer the ground coffee to other and different units without initiating a brewing cycle. Additionally, the apparatus may also have a brewing-only feature in which hot water may be supplied to the brew basket with no initiation of a grinding cycle in the apparatus. Moreover, the basket out switch provides considerable assistance in that it precludes the possibility of operating the device without a basket being positioned properly in place. This avoids accidental spills of grounds and/or hot water. Finally, as can be understood from the description, the apparatus of the present invention may also be supplied with a half grind/brew grind/feature to be combined with the grind-only and brew-only features, thus providing a delivery of lesser amounts of ground coffee, hot water, and/or brewed coffee. It can now be readily appreciated that, in light of a reading of the foregoing description and drawings, those with ordinary skill in the art will be able to make changes and modifications to the present invention without departing from the spirit or scope of the invention as defined in the following appended claims. | A coffee bean grinding and brewing apparatus having a control circuit for initiating grinding and brewing cycles. The control circuit has a brew basket sensing switch that is positioned adjacent the brew basket retaining arms and is engaged into an open position by one of the arms when no basket is positioned between the arms and becomes closed when a basket is positioned between the arms. The control circuit does not initiate any cycle as long as the sensing switch is open avoiding the problem of grounds being delivered accidentally when no basket is present. Additionally, the control circuit has a grind-only switch and a brew-only switch that respectively permit an operator to select a grind-only or a brew only cycle when a basket is held properly between the arms. Finally, the circuit may be provided with a partial and full brew selector switches that permit an operator to select a full and predetermined amount of ground coffee and/or hot water to be delivered to the brew basket or a lesser amount, e.g., one half of the full amount, of ground coffee and/or hot water to the brew basket. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is hereby made to the following copending applications dealing with related subject matter and assigned to the assignee of the present invention:
1. "Standardized Reduced Length Burnable Absorber Rods for a Nuclear Reactor" by Barry R. Cooney et al. assigned U.S. Ser. No. 718,902 and filed Apr. 1, 1985.
2. "Burnable Absorber Rod Push Out Attachment Joint" by Joseph B. Mayers et al., assigned U.S. Ser. No. 774,850 and filed Sept. 12, 1985.
3. "Nuclear Reactor Fuel Assembly With a Removable Top Nozzle" by John M. Shallenberger et al., assigned U.S. Ser. No. 644,758 and filed Aug. 27, 1984, now U.S. Pat. No. 4,631,168.
4. "Improved Guide Thimble Captured Locking Tube in a Reconstitutable Fuel Assembly" by Robert K. Gjertsen et al., assigned U.S. Ser. No. 775,208 and filed Sept. 12, 1985, now U.S. Pat. No. 4,684,500.
5. "Burnable Absorber Rod Releasable Latching Structure" by Robert K. Gjertsen, assigned U.S. Ser. No. 807,142 and filed Dec. 10, 1985, now U.S. Pat. No. 4,684,499.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for insertion and removal of releasable burnable absorber rods from the adapter plate of the top nozzle of a nuclear reactor fuel assembly.
In a typical nuclear reactor, the reactor core includes a large number of fuel assemblies each of which is composed of top and bottom nozzles with a plurality of elongated transversely spaced guide thimbles extending longitudinally between the nozzles and a plurality of transverse support grids axially spaced along and attached to the guide thimbles. Also, each fuel assembly is composed of a plurality of elongated fuel elements or rods transversely spaced apart from one another and from the guide thimbles and supported by the transverse grids between the top and bottom nozzles. The fuel rods each contain fissile material and are grouped together in an array which is organized so as to provide a neutron flux in the core sufficient to support a high rate of nuclear fission and thus the release of a large amount of energy in the form of heat. A liquid coolant is pumped upwardly through the core in order to extract some of the heat generated in the core for the production of useful work.
Since the rate of heat generation in the reactor core is proportional to the nuclear fission rate, and this, in turn, is determined by the neutron flux in the core, control of heat generation at reactor start-up, during its operation and at shutdown is achieved by varying the neutron flux. Generally, this is done by absorbing excess neutrons using control rods which contain neutron absorbing material. The guide thimbles, in addition to being structural elements of fuel assembly, also provide channels for insertion of the neutron absorber control rods within the reactor core. The level of neutron flux and thus the heat output of the core is normally regulated by the movement of the control rods into and from the guide thimbles.
Also, it is conventional practice to design an excessive amount of neutron flux into the reactor core at start-up so that as the flux is depleted over the life of the core there will still be sufficient reactivity to sustain core operation over a long period of time. In view of this practice, in some reactor applications burnable absorber or poison rods are inserted within the guide thimbles of some fuel assemblies to assist the control rods in the guide thimbles of other fuel assemblies in maintaining the neutron flux or reactivity of the reactor core relatively constant over its lifetime. The burnable poison rods, like the control rods, contain neutron absorber material. They differ from the control rods mainly in that they are maintained in stationary positions within the guide thimbles during their period of use in the core. The overall advantages to be gained in using burnable poison rods at stationary positions in a nuclear reactor core are described in U.S. Pat. Nos. to Rose (3,361,857) and to Wood (3,510,398).
Also, the availability of assemblies of burnable absorber rods on a rapid response basis is required at reactor fuel reload time. The present design of the burnable absorber assemblies, being similar to those illustated and described in the first two patent applications cross-referenced above, includes a plurality of precisely spaced apart absorber rods and thimble plugs fastened at their upper ends to a support plate which also mounts a central hold-down device. In view of the multiplicity of components which make up the absorber assemblies and the precise spacing required between them when they are assembled together, it has been found necessary to assemble the absorber assemblies at a manufacturing facility located remote from the reactor site. The final absorber assemblies are then shipped with the fuel assemblies to the reactor site. This means that the particular absorber assembly design must be specified well in advance of the time of actual reload.
A burnable absorber assembly in which the burnable absorber rods have a releasable latching structure is illustrated and described in the fifth patent application cross-referenced above. The advantage of the releasable latching structure is that the configuration of the burnable absorber rods can be specified at the latest possible time because the assembly does not have to include the burnable absorber rods until it is installed. Thus, the nuclear reload design can be fine tuned based on the latest reactor operations input. The ultimate absorber assembly specified may advantageously include, for example, twelve burnable absorber rods and twelve thimble plugs per assembly or other combinations of absorber rods and thimble plugs.
Consequently, a need exists for a device that can be used to insert and remove the burnable absorber rods and thimble plugs from the burnable absorber assembly.
SUMMARY OF THE INVENTION
The present invention provides apparatus for releasably engaging an elongated member, such as a burnable absorber rod or a thimble plug, that is releasably connected to the top nozzle of a nuclear reactor fuel assembly. The top nozzle has an adapter plate disposed at its lower end having at least one passageway therethrough through which the elongated member is disposed. The elongated member has a releasable latching structure at one end that is able to be engaged by the apparatus having at least one latching member movable between a latched position in which the latching member is able to engage said adapter plate and secure the absorber rod in a stationary relationship with respect to the adapter plate and an unlatched position in which the latching member is able to disengage from said adapter plate so that the elongated member be removed from the fuel assembly. The apparatus comprises a hollow releasing member for moving the latching member of the latching structure between its latched position and its unlatched position, an engaging member connected to the releasing member and extending downwardly through the hollow portion of the releasing member, and an actuating member extending downwardly through the hollow portion of the releasing member and coacting with the engaging member to releasably engage the latching structure.
More particularly, the present invention enables a plurality of such elongated members to be inserted or removed from a nuclear reactor fuel assembly and comprises a frame and first and second plates disposed within the frame, the second plate disposed below and spaced apart from the first plate. At least one of the first and second plates is capable of vertical movement relative to the other. The apparatus includes means for moving the frame toward and away from the fuel assembly and means for moving the first and second plates within the frame toward and away from the adapter plate of the top nozzle of the fuel assembly. The apparatus thus includes means for varying the vertical distance between the first and second plates between a first distance and a decreased second distance. Means associated with the first and second plates maintains the first and second plates in a position whereby the vertical distance between said plates is the second distance. Further, the apparatus includes a hollow releasing member extending downwardly from the second plate for moving the latching member of the latching structure between its latched position and its unlatched position, an engaging member connected to the releasing member and extending downwardly from the second plate through the hollow portion of the releasing member, and an actuating member extending downwardly from the first plate through the hollow portion of the releasing member and coacting with the engaging member to releasably engage the latching structure when the vertical distance between the first and second plates is the second distance.
The present invention coacts with the releasable latching structure that secures the burnable absorber rods and thimble plugs to the top nozzle adapter plate of a nuclear reactor fuel assembly so that the final arrangement of the absorber rods and thimble plugs can be specified at the reactor site. Thus, the latest reactor operating information can be considered when determining the arrangement of the absorber rods and thimble plugs in the design of the fuel assembly. The approach avoids the need for off site manufacturing of the final absorber rod and thimble plug assemblies. Instead, an inventory of individual absorber rods and thimble plugs can be sent to the reactor site prior to fueling the reactor. Once the design of the fuel assembly is specified, the configuration of the absorber rods and thimble plugs can be inserted in the fuel assembly. Later, the spent absorber rods can easily be released from the top nozzle adapter plate and replaced.
These and other advantages and attainments of the present invention will become apparent to those skilled in the art upon reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of the following detailed description, reference will be made to the attached drawings in which:
FIG. 1 is a side elevational view of a gripper assembly, constructed in accordance with the present invention, disposed above a nuclear reactor fuel assembly illustrating the gripper assembly in a raised position gripping absorber rods;
FIG. 2 is an enlarged side elevational view of a portion of the gripper assembly of FIG. 1;
FIG. 3 is an enlarged, detailed sectional view of a portion of a gripper assembly constructed in accordance with the present invention including an absorber rod extending in a guide thimble with the releasable latching structure of the absorber rod securing the absorber rod to the top nozzle adapter plate;
FIG. 4 is an enlarged elevational view of the lower portion of the releasable latching structure shown in FIG. 3 rotated 90 degrees;
FIG. 5 is a sectional view of the mounting body of the releasable latching structure taken along line FIG. 5--FIG. 5 of FIG. 4;
FIG. 6 is an enlarged detailed elevational view of the gripper assembly as shown in FIG. 3 of the present invention showing the actuating sleeve, in section, extended downwardly along the spring latch so as to forcibly engage and deflect all of the latch fingers of the spring latch inward to their unlatched positions and showing the gripper flexures disposed within an undercut cavity in the top portion of the mounting body of the releasable latching structure;
FIG. 7 is an enlarged detailed elevational view of the gripper assembly as shown in FIGS. 3 and 6 showing the actuating sleeve, in section, the gripper flexures disposed within an undercut cavity in the top portion of the mounting body of the releasable latching structure and showing the actuator rod in a lowered position thus forcibly extending grippers outwardly so as to engage the sides of the undercut cavity of the mounting body;
FIG. 8 is an enlarged elevational view of the gripper assembly as seen in FIGS. 3, 6 and 7 showing the releasable absorber rod being removed from the fuel assembly;
FIG. 9 is a schematic view of the latching mechanism of a gripper assembly showing the actuator in its operating position in contact with the latch releasing the lower plate from the adapter plate; and
FIG. 10 is a schematic view of the latching mechanism of a gripper assembly showing the adapter plate and lower plate secured together by the latching mechanism and the actuator in its lowered position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIG. 1, there is shown an elevational view of a gripper assembly 10 of the invention disposed above a nuclear reactor fuel assembly 12, represented in vertically foreshortened form. The fuel assembly 12 includes a number of longitudinally extending guide tubes or thimbles 14 which project upwardly from a bottom nozzle (not shown). The assembly 12 further includes an organized array of elongated fuel rods 16 transversely spaced and supported by axially spaced transverse grids. The assembly 12 has a top nozzle 18 removably attached to the upper ends of the guide thimbles 14 to form an integral assembly capable of being conventionally handled without damaging the assembly parts.
As mentioned above, the fuel rods 16 in the array thereof in the fuel assembly 12 are held in spaced relationship with one another by grids spaced along the fuel assembly length. Each fuel rod 16 includes nuclear fuel pellets and the opposite ends of the rod are closed by upper and lower end plugs to hermetically seal the rod. The fuel pellets, composed of fissile material, are responsible for creating the reactive power of the nuclear reactor. A liquid moderator/coolant such as water, or water containing boron, is pumped upwadly through the fuel assemblies of the core in order to extract heat generated therein for the production of useful work.
In the operation of a nuclear reactor, it is common practice to provide an excess of reactivity initially in the reactor core and, at the same time, provide means to maintain the reactivity relatively constant over its lifetime. Such means commonly takes the form of control rods (not shown) supported for movement into the guide thimbles of some fuel assemblies in the core and burnable absorber rods 20 supported stationarily in the guide thimbles 14 of other fuel assemblies in the core. The stationary absorber rods 20 assist the movable control rods in maintaining a substantially constant level of neutron flux or reactivity in the core throughout its operating cycle. Before describing the means of the present invention for releasably engaging a burnable absorber rod, the means for stationarily attaching the burnable absorber rods 20 to the top nozzle 18 will be briefly described.
As illustrated in FIGS. 3, 6, 7 and 8, the top nozzle 18 includes a lower adapter plate 22 having a plurality of passageways 24 (only one being shown) formed therethrough. Each guide thimble 14 has its uppermost end portion coaxially positioned within one passageway 24 in the adapter plate 22 and is removably connected to the adapter plate 22 by attaching structure 26, which provides a plurality of structural joints between the top nozzle 18 and the guide thimbles 14 of the fuel assembly skeleton. The attaching structure 26 is generally the same as illustrated and described in U.S. Pat. Nos. 4,631,500 and 4,684,500 cross-referenced above.
Absorber rods 20 are disposed within guide thimbles 14 and extend through passageways 24 of adapter plate 22. The absorber rods 20 are releasably secured to adapter plate 22 by releasable latching structures 28. Releasable latching structure 28 is more fully described in U.S. Pat. No. 4,684,499 cross-referenced above, but will be described herein to the extent necessary to facilitate an understanding of the present invention.
Releasable latching structure 28 includes a generally cylindrical mounting body 30 (FIGS. 3, 4 and 5) and a generally cylindricaly spring latch 32. The mounting body 30 is composed of a generally cylindrical lower plug portion 34 attached to and sealing the upper end of the absorber rod 20 and a generally cylindrical upper end portion 36 having an annular circumferential groove 38 defined thereabout. An undercut cavity 40 formed in the uppermost surface of the upper end portion 36 of the mounting body 30 is configured to receive the gripper assembly 10 of the invention for use in the insertion and removal of the absorber rods 20 from guide thimbles 14. The mounting body 30 has a generally conical configuration tapering inwardly from the upper end portion 36 to the lower plug portion 34 so as to define a tapering recessed void region 42, which surrounds the mounting body 30 at the middle portion thereof. Mounting body 30 has a plurality, preferably four, circumferentially spaced projections 44 disposed at 90 degree intervals about its lower end just above plug portion 34. Projections 44 are designed to extend over the top surface of adapter plate 22 when an absorber rod 20 is disposed within a guide thimble 14.
The spring latch 32 of the latching structure 28 is composed of a generally cylindrical outer ring portion 46 disposed about the upper end portion 36 of the mounting body 30 and a plurality, preferably four, circumferentially spaced latch fingers 48 connected at their upper ends to the outer ring portion 46 in cantilever fashion and extending downwardly therefrom along the mounting body 30. Latching fingers 48 are disposed at 90 degree intervals and extend downwardly between projections 44 (FIG. 5). The outer ring portion 46 has an annular circumferential groove 50 associated annular circumferential bulge 52 defined therein. Circumferential bulge 52 coacts with to the circumferential groove 38 in the upper end portion 36 of latching structure 28 so as to connect the spring latch 32 to the mounting body 30.
The latch fingers 48 have external latching keys 54 defined on their lower ends and are radially deflectible toward and away from the mounting body 30 between a outer latching position as seen in FIG. 3 and an inner unlatching position as seen in FIGS. 6, 7 and 8. The normal relaxed position to which each of the fingers 48 is biased to return is the latching position. When releasable latching structure 28 is holding absorber rods 20 in place within guide thimbles 14, latch fingers 48 are in their outer latching position and the latching keys 54 are engaged within recess 56 of a passageway 24 in adapter plate 22.
As shown in FIG. 1, gripper assembly 10 is housed within support frame 58, which is disposed above fuel assembly 12. Gripper assembly 10 is attached to the lower portion of mast 60 by a bracket 62. Mast 60 is moved vertically between an upper and lower position by a mechanism, not shown, to raise and lower gripper assembly 10 with respect to fuel assembly 12. Comb assembly 64 provides some guidance and support for absorber rods 20 as they are raised from or lowered into fuel assembly 12. A recess is provided in each of the four lower corners of frame 58 to receive a guide pin 66, mounted on top of the fuel assembly 12 to orient the frame 58 as it is lowered onto fuel assembly 12 for use.
As shown in FIGS. 2, 3, 6, 7 and 8, the gripper assembly 10 of the present invention includes actuator plate 68 and lower plate 70 disposed below and spaced apart from actuator plate 68. Actuator plate 68 is movable vertically with respect to lower plate 70 between a first distance and a closer second distance. A center support 72 is fixedly secured to actuator plate 68 and extends through bores in the center of both actuator plate 68 and lower plate 70, thus securing the plates 68 and 70 together. Center support 72 includes a circumferential flange 74 at its lower end which is capable of supporting lower plate 70 when the gripper assembly 10 is not engaging an absorber rod 20.
Lower plate 70 includes a plurality of hollow cylindrical actuating sleeves 76 extending downwardly from lower plate 70. Actuating sleeves 76 are spaced so that they will extend over an absorber rod 20 as gripper assembly 10 is lowered over fuel assembly 12. Actuating sleeves 76 are of a size appropriate for causing keys 54 of latch fingers 48 to disengage from adapter plate 22 of the top nozzle 18 of the fuel assembly 12 as an actuating sleeve 76 is lowered over an absorber rod 20. Each actuating sleeve 76 further includes an annular circumferential bulge 78 on its inner surface which engages an annular circumferential groove 50 of a spring latch 32 as actuating sleeves 76 are lowered over absorber rods 20.
Hollow cylindrical positioning sleeves 80 are attached to lower plate 70 and extend part way through the hollow portions 82 of actuating sleeves 76. The bottom surface 81 of each positioning sleeve 80 rests on the upper surface 83 of a mounting body 30 of a releasable latching structure 28 when gripper assembly 10 is lowered over absorber rods 20. Contact between bottom surfaces 81 of positioning sleeves 80 and the upper surfaces 83 of mounting bodies 30 prevents further downward motion of gripper assembly 10.
Gripper flexures 84 extend through the hollow portions 86 of positioning sleeves 80 past the bottom surfaces 81 of positioning sleeves 80. Gripper flexures 84 include grippers 88 which are received within undercut cavities 40 of mounting bodies 30 as gripper assembly 10 is lowered over absorber rods 20.
Actuator rods 90 extend from actuator plate 68 downwardly through hollow portions 92 between gripper flexures 84. As actuator plate 68 moves downwardly with respect to lower plate 70 between the first and second distance, actuator rod 90 contacts shoulders 91 and then inner surfaces 93 of grippers 88 to spread grippers 88 of gripper flexures 84 apart. Thus, when grippers 88 of gripper flexures 84 are disposed within undercut cavities 40 of mounting bodies 30, actuator rods 90 spread grippers 88 of gripper flexures 84 apart to securely engage the sides of undercut cavities 40.
As shown in FIGS. 1, 2, 9 and 10, a plurality of latches 94 are attached to actuator plate 68 by pins 96. Each latch includes upper and lower fins 98 and 100, respectively. Latches 94 are normally biased in the locked position by a torsion spring 102. Lower fins 100 of latches 94 include flat shelf portions 104, which support lower plate 70 when latches 94 are oriented in the locked position and the distance between actuator plate 68 and lower plate 70 is the second distance (FIG. 10).
Actuators 106 are used to release latches 94 from their locked positions. Actuators 106 include a stem portion 108 by which actuators 106 are attached to frame 58 through mounting means 110. Enlarged portions 112 at the lower ends of stems 108 contact upper fins 98 of latches 94 to unlock latches 94 (FIG. 9). Actuators 106 are attached to frame 58 so that they are movable along a vertical path between a lower, normal position (FIG. 10) and a raised, operating position (FIG. 9). Actuators 106 can be activated only when the gripper assembly 10 is at the lower end of its travel.
In order to remove an absorber rod 20 from the top nozzle 18 of a fuel assembly 12, the gripper assembly 10 is lowered onto fuel assembly top nozzle 18. Actuator plate 68 and lower plate 70 are held in a first spaced relationship. Actuator plate 68 is supported by bracket 62 and lower plate 70 is supported by flange 74 of center support 72. As the gripper assembly 10 is lowered onto fuel assembly top nozzle 18, actuating sleeves 76 are lowered over releasable latching structures 28, which are releasably securing absorber rods 20 to adapter plate 22 of top nozzle 18 (FIG. 3). As each actuating sleeve 76 moves down over a releasable latching structure 28, an annular circumferential bulge 78 of an actuating sleeve 76 is eventually retained within an annular circumferential groove 50 of an outer ring portion 46 of a spring latch 32. Fingers 48 of each spring latch 32 are gradually forced inward toward a mounting body 30 until the latching keys 54 are disengaged from a recess 56 in passageway 24 in adapter plate 22. At the same time, each gripper flexure 84 gradually enters an undercut cavity 40 of a mounting body 30. Downward movement of gripper assembly 10 stops when the bottom surfaces 81 of positioning sleeves 80 contact the uppermost surfaces 83 of the upper end portions 36 of mounting bodies 30 of releasable latching structures 28 (FIG. 6). Use of positioning sleeves 80 prevents gripper flexures 84 from bottoming out in the undercut cavities 40 of the releasable latching structures 28, thus ensuring smooth operation of the gripper flexures 84.
The actuator plate 68 is then lowered with respect to lower plate 70. As actuator plate 68 is lowered, each actuating rod 90 gradually enters hollow portions 92 between gripper flexures 84 contacts shoulders 91 and then inner surfaces 93 of grippers 88 and gradually pushes grippers 88 apart to a position wherein the grippers 88 of gripper flexures 84 are securely engaged within undercut cavities 40 of mounting bodies 30 of releasable latching structures 28 (FIG. 7). Absorber rods 20 can then be withdrawn from guide thimbles 14 and removed from the fuel assembly 12 by raising the gripper assembly 10 (FIG. 8).
The actuator plate, 68 and the lower plate 70 are held together in this closer, spaced relationship as the gripper assembly 10 is raised by latches 94. After lower plate 70 reaches its lowest point of travel, actuators 106 are raised to their operating position (FIG. 9). As the actuator plate 68 is lowered with respect to the lower plate 70, so that gripper flexures 84 securely engage absorber rods 20, actuators 106 contact upper fins 98 of latches 94 causing latches 94 to rotate counterclockwise (FIG. 9). As a result, flat shelf portions 104 of latches 94 clear the top surface and outer edges of lower plate 70 and snap under lower plate 70 so that flat shelf portions 104 of latches 94 support the lower surface of lower plate 70 (FIG. 10).
In order to insert an absorber rod into the fuel assembly top nozzle 18, the gripper assembly 10 is lowered onto fuel assembly top nozzle 18 with actuator plate 68 and lower plate 70 held in their second spaced apart relationship with latches 94 in their locked position and flat shelf portions 104 of latches 94 supporting the lower plate 70. Absorber rods 20 are secured by gripper assembly 10 as actuator rods 90 are disposed within hollow portions 92 between gripper flexures 84 keeping grippers 88 in their spaced apart position so that they are securely engaged within cavities 40 of mounting bodies 30 of releasable latching structures 28. Downward movement of gripper assembly 10 stops when the bottom surfaces 77 of actuating sleeves 76 contact the upper surface 23 of top nozzle adapter plate 22. In this position, absorber rods 20 are inserted within passageways 24 of top nozzle adapter plate 22 but are still secured by grippers 88 of gripper assembly 10 (FIG. 7). Actuators 106 are then raised until they contact upper fins 98 of latches 94 causing latches 94 to rotate counterclockwise (FIG. 9). As a result, flat sheet portions 104 of latches 94 clear the lower surface and outer edges of lower plate 70 releasing lower plate 70 (FIG. 9). As gripper assembly 10 is raised, actuator plate 68 is raised with respect to lower plate 70 until actuator plate 68 and lower plates 70 are in their first spaced apart relationship whereby actuator plate is supported by bracket 62 and lower plate 70 is supported by flange 74 on center support 72. As actuator plate 68 is raised with respect to lower plate 70, actuator rods 90 are withdrawn from recesses 92 between gripper flexures 84 so that grippers 88 no long securely engage undercut cavities 40 of mounting bodies 30 of releasable latching mechanisms 28 (FIG. 6). Further upward movement of the gripper assembly 10 raises actuator sleeves 76 from the upper surface of top nozzle adapter plate 22. As actuator sleeves 76 are raised, latch fingers 48 of releasable latching structure 28 are released and keys 54 of latch fingers 48 engage recesses 56 in passageway 24 in adapter plate 22, thus, securing absorber rods 20 to top nozzle adapter plate 22 through releasable latching structures 28 (FIG. 3). | Apparatus for releasably engaging an elongated member that is releasably connected to the top nozzle of a nuclear reactor fuel assembly. The top nozzle has an adapter plate disposed at its lower end having at least one passageway therethrough through which the elongated member is disposed. The elongated member has a releasable latching structure at one end that is able to be engaged by the apparatus, having at least one latching member movable between a latched position in which the latching member is able to engage said adapter plate and secure the absorber rod in a stationary relationship with respect to the adapter plate and an unlatched position in which the latching member is able to disengage from said adapter plate so that the elongated member be removed from the fuel assembly. The apparatus comprises a hollow releasing member for moving the latching member of the latching structure between its latched position and its unlatched position, an engaging member connected to the releasing member and extending downwardly through the hollow portion of the releasing member, and an actuating member extending downwardly through the hollow portion of the releasing member and coacting with the engaging member to releasably engage the latching structure. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND
This disclosure relates generally to machines for preparing shaved ice confectioneries, and more particularly, but not necessarily entirely, to a block ice shaver that is particularly adapted for producing a light, fluffy, finely textured shaved ice, or powdered snow-like flavored food products.
A variety of machines have been developed, described and are widely known for creating or processing cold deserts and confectioneries by processing ice into more appealing eatable forms, such as snow cones and shaved ice. Such devices produce either ice granules (snow cones) or light, fluffy, finely textured shaved ice for subsequent flavoring using syrups. For consistency, a block of ice can produce more appealing ice shavings than cubed ice, for example.
Despite the advantages of shaved ice machines that are available in the marketplace, improvements are still being sought. Machines in the marketplace may have limitations such as, cumbersome ice block change procedures, frozen and impacted blades, blades that do not produce light, fluffy, finely textured shaved ice, and may produce inconsistent shaved ice textures because the feeding of an ice block into a blade is inconsistent or because the machine cannot adapt to the changing consistency of the ice as the block of ice begins to warm and melt. Such machines that may use large blocks of ice tend to operate at a relatively slow rate, require significant maintenance, and are incompatible with either home use or large volume use.
Further, such machines may not be able to accommodate the changes in the texture of the block of ice as the ice begins to warm. As ice begins to warm and changes from a very cold state to a warmer state, the texture and consistency of the ice to be shaved by a machine begins to change. As the ice warms, the texture of the ice begins to degrade and the quality of the shaved ice decreases making it more difficult for the machine to shave the warm ice, or at least the ability to provide a high quality shaved ice product is decreased because of the interaction between the blade of the machine and the ice block.
Machines in the marketplace may thus be characterized by several disadvantages that may be addressed by the disclosure. The disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.
The features and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation and are readily apparent to those of ordinary skill in the art upon review of the following drawings, detailed description, claims and abstract of this disclosure. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
FIG. 1 illustrates a side, perspective view of an embodiment of an ice shaving machine made in accordance with the principles of the disclosure;
FIGS. 2 a and 2 b illustrate the loading of an ice block into an embodiment of an ice shaving machine made in accordance with the principles of the disclosure;
FIG. 3 illustrates a schematic view of several components of an embodiment of an ice shaving machine consistent with the principles of the disclosure;
FIG. 4 illustrates an embodiment of a blade holder consistent with the principles of the disclosure;
FIG. 5 illustrates a cut away view of an embodiment of a blade holder consistent with the principles of the disclosure;
FIG. 6 illustrates a schematic, top view of an embodiment of a blade consistent with the principles of the disclosure;
FIG. 7 illustrates an embodiment of a method and associated structures that allow the rotation of a blade relative to a blade holder in accordance with the principles of the disclosure;
FIG. 8 illustrates the concept of tensioning of an embodiment of an ice shaving blade within a blade assembly consistent with the principles of the disclosure;
FIG. 9 illustrates an embodiment of a tensioned blade attached to a blade holder and forming blade assembly consistent with the principles of the disclosure;
FIG. 10 illustrates the feature of a flexible blade consistent with the principles of the disclosure;
FIG. 11 illustrates an embodiment of a blade holder having enhanced features consistent with the principles of the disclosure;
FIGS. 11 a and 11 b illustrate a top and side view, respectively, of an embodiment of a blade holder consistent with the principles of the disclosure;
FIG. 12 illustrates a schematic view of an embodiment of an ice shaving machine having a single drive shaft for actuating the ice block feeder;
FIG. 13 illustrates an embodiment of a blade consistent with the principles of the disclosure;
FIG. 14 is a detailed view of the embodiment of a blade illustrated in FIG. 13 illustrating the cutting surfaces and slots consistent with the principles of the disclosure;
FIGS. 15 a and 15 b illustrate a side view and a side cross-sectional view of an embodiment of a blade in accordance with the principles of the disclosure;
FIGS. 16 a , 16 b and 16 c illustrate top views of various blade embodiments in accordance with the principles of the disclosure; and
FIG. 17 illustrates and embodiment of a safety clearing tool for use with an ice shaving system disclosed herein.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.
Before the apparatus, system and methods for shaving ice, such as blocks of ice, are disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the disclosure will be limited only by the appended claims and equivalents thereof.
In describing and claiming the subject matter of the disclosure, the following terminology will be used in accordance with the definitions set out below.
It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.
As used herein, the phrase “consisting of” and grammatical equivalents thereof exclude any element, step, or ingredient not specified in the claim.
As used herein, the phrase “consisting essentially of” and grammatical equivalents thereof limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic or characteristics of the claimed disclosure.
The disclosure discloses an ice shaving machine for receiving a block of ice and thinly slicing such block ice to produce a powdery snow-like textured confection. It should be noted that for the purposes of this disclosure an ice block is defined as a generally homogenous solid body or mass of ice having a volume that is greater than or equal to eight cubic inches or that is larger than a typical household ice cube that may be placed inside of a user's cup to cool a drink. The ice block may be placed in a feeder, which permits the block to come into contact with a blade. The blade shaves off paper-thin slices of ice. A collector collects the paper-thin slices of ice and moves it to a spout, under which a container is placed to receive the slices of ice. Once the container is sufficiently full, flavorings may be added, either through an integrated flavor dispensing system or from an individual flavor container or from a stand-alone flavor stations having a plurality of containers. This disclosure has various embodiments and alternative blade designs, which are described in detail in the following detailed discussion.
FIG. 1 illustrates a perspective view of an embodiment of an ice shaving machine 100 of the disclosure. The machine 100 is shown having a cabinet 114 , which may be made of various materials, including stainless steel, a light-weight fiberglass or plastic material without departing from the scope or concept of the disclosure, for durability and ease of cleaning. It will be appreciated that various embodiments of the machine 100 may comprise one or more of the following features: a blade assembly 310 , including a blade holder 301 and a blade 101 ; a safety cover or blade cover assembly 102 , including a spout 105 , lid 111 and an ice block guide 113 ; an ice block feeder 103 , including at least one drive shaft 116 ; a main drive motor 305 for rotating the blade assembly 310 ; and at least one motor 316 for actuating the at least one drive shaft 116 . The machine 100 may also comprise a flavor dispenser 104 .
A safety cover 102 may be attached to the top of the cabinet 114 for receiving a block of ice 107 and covering the working parts of the machine, for example the blade assembly 310 . The safety cover 102 may be composed of a generally clear “lexan” plastic material, although other sufficiently hard materials may also suffice and are meant to fall within the scope of the disclosure. The safety cover 102 may have a base portion 109 for covering the blade assembly 310 . The base portion 109 may be an outer shell fitting over and around the blade and blade assembly.
A spout assembly 105 may also be present and may be a separate component from the cover 102 . The spout assembly 105 may comprise a domed portion for providing a domed round top of shaved ice for the produced product and may also comprise an outer shell or base portion 109 fitting over and around the blade 101 and the blade holder 301 , which comprise a blade assembly 310 . The spout 105 and the outer shell or base portion 109 may be in mechanical communication with each other, such that shaved ice may move from the interior of the outer shell or base portion 109 through a conduit 105 a to the spout 105 for dispensing the shaved ice into a container (illustrated best in FIG. 1 ). It will be appreciated that the spout 105 may be shaped other than as a dome and may be part of, or separate from, the safety cover 102 and even the spout assembly. For example, the spout 105 may be in mechanical communication with the base portion 109 of the spout assembly, or the spout 105 may be attached directly to the cabinet 114 or other structural member, such that the spout 105 is not in mechanical communication with the spout assembly, without departing from the scope of the disclosure.
The spout assembly may also comprise a flap 117 that may be a flexible material, such as a plastic or other material that is durable, but pliable, to help and assist a user in making a shaved ice confection. The flap 117 may be used as a part of the spout assembly or may be a separate and distinct component. The flap 117 may be used as a guide to assist in the dispensing of the shaved ice, such that less shaved ice is lost as the shaved ice is dispensed from the spout 105 to the container. The flap 117 may at least partially wrap around the container and may be used, or operated, as a chute so that shaved ice is directed into the container as the shaved ice is dispensed from the spout 105 .
Mounted to the safety cover 102 is a lid 111 that may be movably fastened to the safety cover 102 . In the embodiment, an electrical or mechanical switch 112 is provided in the lid 111 safety cover 102 connection to shut off the operation of the machine 100 when the lid 111 is raised. The lid 111 may further comprise an ice block guide 113 that adds a biasing force laterally to the ice block so that the ice block will be more consistently fed into the blade 101 . The ice block guide 113 may be a simple compliant type structure or may have a plurality of parts that produce a biasing force.
An ice block feeder 103 may comprise, or may be mounted or otherwise attached to, a drive shaft 116 . The ice block feeder 103 may operate to contact the block of ice and place a force on said block of ice. The drive shaft 116 operates to actuate the ice block feeder 103 into contact with the ice block, thereby bringing and forcing the ice block 107 into contact with the blade 101 . The ice block feeder 103 may comprise or may be mounted or otherwise attached to a single drive shaft 116 or, alternatively, to two or more drive shafts 116 . When two or more drive shafts 116 are utilized, the drive shafts 116 work in unison to force, move and push the ice block into contact with the blade 101 to produce shavings of ice. The ice block feeder 103 may continuously move the ice block into the blade 101 , freeing flakes or shavings of ice, which are received by the spout 105 of the blade cover assembly 102 .
It will be appreciated that the blade 101 may be generally planer, generally circular, substantially flat and slotted with a plurality of slots or openings 151 (shown best in FIGS. 6 , 13 - 15 b ). However, it will be appreciated that the blade 101 may be another geometric shape, besides circular, without departing from the scope of the disclosure. Each slot or opening 151 may have an adjacent edge 150 that may be slightly bent upwards toward the direction of the incoming ice block. This blade 101 may be made of high quality stainless steel material to maximize the blade life and reduce corrosion. Other non-corrosive high strength materials may also be used in place of stainless steel without departing from the scope of the disclosure. The blade 101 may be affixed to a blade holder 301 to form a blade assembly 310 such that the assembly can be rotated to provide more consistent ice shavings. While in use, the ice shavings fall through the blade 101 by way of the slots 151 and into a collection area where the shavings are moved toward the spout 105 and are then available to be dispensed as desired into a container. Once a sufficient quantity of ice shavings are collected in a container, flavoring may be added as desired.
A flavor dispenser 104 may be provided. In an embodiment of the disclosure 100 , flavor selection switches may be provided on the front of the cabinet 114 . The flavors may be provided by a plurality of inverted bottles or other containers (not shown), which may be fitted to receptacles on the top of the cabinet 114 . An automated water switch may also be provided to flush or clean the flavoring from the dispenser system. The water can also be used to dilute the concentrated flavoring. A drain pan may be provided with a drain, which may have a drain hose for handling spills.
FIGS. 2 a and 2 b illustrate an embodiment of a block ice shaving machine 100 while it is being used. More particularly, FIGS. 2 a and 2 b illustrate the loading of an ice block 107 into the ice shaving machine 100 . During use, a user slides the lid 111 in an upward direction to an open position. As can be seen in FIG. 2 a , this movement is illustrated by the upward pointing arrow. In the open position, access to the ice block feeder 103 is provided and an ice block 107 can be loaded into position over the blade 101 . It will be appreciated that the structural features of the cover 102 permit a user to gain access to the ice block 107 , even after the ice block 107 has been loaded into the machine 100 . The ability to access the block of ice 107 after being loaded into the machine 100 may be advantageous for several reasons, including the ability to clear blocked shaved ice from the blade 101 or the spout assembly 105 or removing unused portions of the block of ice and potentially others. Some machines that are available in the market do not allow or otherwise permit access to the ice once it is loaded into the machine. The result of those machines is that time and effort may be wasted while the machine either works to clear itself of frozen or otherwise stuck shaved ice, or simply shaves the excess ice that is loaded in the machine as waste product.
The ice block feeder 103 may be raised automatically or manually to allow the insertion of an ice block 107 into an opening or space between the ice block feeder 103 and the blade 101 . An electronic switch may be provided to control the position and travel of the ice block feeder 103 . The electronic switch, whether a toggle switch or a rocker switch, may control at least one electric motor 316 (illustrated best in FIG. 3 ) in order to raise and lower the ice block feeder 103 . A voltage regulator/transformer may receive AC power via a standard three prong power cord and produces DC electric power for the motor 316 . Between the voltage regulator/transformer and the motor 316 may be a speed controller, which includes a motor speed selection dial (not shown). The voltage regulator/transformer may be connected via an electric connection to the speed controller, which in turn, is connected to the motor 316 . The motor may be a DC motor capable of turning the shaft at between 400 and 500 rpm. Alternatively, it is contemplated that an AC motor capable of 1100 rpm may be substituted. Other motor configurations can be substituted without departing from the concept of the disclosure. The motor 316 may be connected to one or more drive shafts 116 to drive the ice block 107 into the blade 101 at a predetermined rate and at a predetermined pressure.
One embodiment may comprise an ice block feeder 103 that drives the ice block 107 within a range at about 180 to about 220 lbs. of pressure. In another embodiment, an ice block feeder 103 may apply more or less pressure than previously stated in the range, and may further use gravity and the mass of the ice block 107 itself to feed the ice block 107 into the blade 101 . As can be seen in FIG. 2 b the lid 111 may be rotated to lock into an open position for convenience. Other mechanisms may be employed to lock the lid 111 in an open position and are contemplated to be with in the scope of the disclosure.
FIG. 3 illustrates a schematic view of an ice block shaved ice machine 100 . An embodiment of a block ice shaving machine 100 may comprise a main drive motor 305 that may be mechanically coupled or connected to a blade assembly 310 , or directly to a blade 101 , configured for shaving ice from an ice block. The mechanical coupling may be accomplished through additional structures such as gearing and pulleys or by blade holders 301 . A control mechanism for activating and deactivating the mechanical drive mechanism, such as the main drive motor 305 may be used to operate the machine. For example, the control mechanism may comprise a switch device to control the main drive motor 305 , which may be actuated by actuating the switch device. The switch device may be a toggle switch or a rocker switch, which may advantageously provide a safety mechanism such that there is substantially no chance of accidental bumping of the switch into an activated position. The main drive motor 305 may also be actuated using a foot pedal switch.
In an embodiment a blade 101 may be attached to a blade holder 301 , and it is the blade holder 301 that may be directly attached to the drive shaft 307 of the main drive motor 305 . A blade holder 301 and blade 101 may be assembled together using complementary structures to form a blade assembly 310 . It will be appreciated that the blade 101 may be attached or otherwise connected to the blade holder 301 using a variety of different mechanical structures. For example, threaded inserts and fasteners, screw fasteners, key and keyhole fasteners, post or prong style snap fasteners, mechanical pins, clips or hooks, anchors, bolts, clamps, locknuts, rivets, screws and washer assemblies, or other fasteners known or that may be become known in the future may be used to attach or connect the blade 101 to the blade holder 301 without departing from the scope of the disclosure.
An ice block shaved ice machine 100 may further comprise an ice block feeder 103 that comprises, or is connected to, one or more drive shafts 116 . The drive shafts 116 may operate by way of a screw drive rod 317 that is driven by an ice block feeder electric motor 316 . The drive shafts 116 may be connected one to another with a push plate 303 that actually makes contact with the block of ice 107 . Electronic controls may be employed to control any block feeder electric motors 316 as well as the main drive motor 305 . In an embodiment the main drive motor 305 may be mechanically coupled to the blade assembly 310 through a transmission or gear box (not shown) having predetermined operational inputs and outputs. As can be seen in FIG. 12 , it is within the scope of the disclosure to contemplate an ice block shaving machine 1200 having more or less drive shafts 116 . The ice block shaving machine 1200 may have a single drive shaft 116 and may have additional structures to allow the successful use of a single drive shaft 116 , such as a single motor 316 .
FIG. 4 illustrates a top down view of blade holder 301 of a blade assembly 310 . In the embodiment it can be seen that the blade holder 301 may comprise a plurality of arms 404 . The drawings illustrate, for exemplary purposes only, embodiments having three or four arms, but it will be appreciated that the plurality of arms 404 may include two, three, four or more arms without departing from the scope of the disclosure.
In an embodiment, and as illustrated in FIG. 4 , the blade holder 301 may comprise a plurality of arms 404 , for example three arms 404 . The plurality of arms 404 may each radiate out from a central hub 406 . At some distance from the center hub 406 , a fastening or attachment structure 410 may be disposed on each of the plurality of arms 404 . The fastening or attachment structure 410 may correspond with an attachment point (such as 615 in FIG. 6 or 706 in FIG. 7 ) of the blade 101 . The fastening or attachment structure 410 may be used to fasten the blade 101 to the blade holder 301 .
It will be appreciated that a radial measurement from a center of rotation of the blade holder 301 , which center of rotation may be the center of the hub 406 , to the attachment structure 410 of each of the plurality of arms 404 is less than a radial measurement from a center of rotation of the blade 101 to the attachment points (such as 615 of FIG. 6 ) of the blade 101 . The result may be that the blade 101 is in a tensioned state as discussed more fully below with respect to FIGS. 8 and 9 .
The center hub 406 may comprise a blade support that mechanically communicates and interacts with the blade to control the amount of flex of the blade as a load is placed on the blade. The result may be that the blade is loaded evenly thereby reducing wear and tear of the blade, which may extend the life of the blade.
In an embodiment a blade 101 may be attached to a blade holder 301 , and it is the blade holder 301 that is directly attached to the drive shaft 307 of the main drive motor 305 . It should be noted that the blade holder 301 may be directly attached to a drive shaft of a motor with any manner of known means, such as complementary threaded portions, set screws or any other means known or yet to be discovered. With regard to the number of arms 404 of the blade holder 301 , it may be advantageous to have enough arms 404 to control forces on the blade 101 and resist undesired rotation. For example, three arms 404 , as illustrated in FIG. 4 , would provide the desired stability in the typical “x” and “y” planes, such that the machine 100 will work relative to a single axis of rotation. It will be appreciated that the single axis of rotation may be a vertical axis or a horizontal axis of rotation. It will be appreciated that the single axis of rotation may be coaxial with a shaft, such as 307 , of a drive motor, such as 305 , in a simple embodiment. Alternatively, the single axis of rotation may not be coaxial or even parallel to a shaft, such as 307 , of a drive motor, such as 305 , if gearing is to be used in the machine.
Referring now to FIG. 5 , the figure illustrates a cut-a-way view of a blade holder 301 defined by the cut lines AA-AA as shown in FIG. 4 . In the cut-a-way view, greater detail regarding the center hub 406 is shown and which comprises a driver interface 513 having threads 514 that are schematically shown for this embodiment. A drive shaft (not shown) of an appropriate electric motor (not shown) may be inserted into the driver interface 513 and may be affixed by threading the threads 514 of the blade holder 301 onto corresponding threads on said drive shaft. The threads may be reverse threaded or traditionally threaded such that during use the blade holder 301 does not separate from the drive shaft. The blade holder may also be held with a set screw or key slot structure.
As can further be seen in FIG. 5 , the plurality of arms 404 may comprise additional structures and structuring in order to provide desired functionality. For example, as illustrated in FIG. 5 , a pass-through portion 525 may be provided that allows ice shavings to pass over the top of the arm 404 yet under the blade 101 , such that the ice shavings can freely move and be forced into a collection area and out of the spout. The pass through portion 525 may be defined by the attachment structure 410 on one end and the hub 406 on the other end as illustrated in FIG. 5 and FIG. 11 b . Referring briefly to FIG. 11 b , the pass through portion 525 allows the ice shavings to easily pass over the top of the arm 1104 because of the height of the material forming the arm 1104 . As illustrated in the embodiment of FIG. 11 b , the arm 1104 may be formed by a sloping or tapered portion 1104 a adjacent the hub 1106 , which tapers in a proximal-to-distal direction with respect to the hub 1106 . The tapered portion 1104 a is immediately followed by a substantially planar portion 1104 b . It will be appreciated that there may be a pass-through portion 525 for each of the plurality of arms 404 (illustrated best in FIGS. 5 , 9 - 11 b ). Accordingly, while ice is being shaved from a block of ice, the shavings will be allowed to fall through the slots or openings 151 in the blade 101 and into a collection area that is away from the blade 101 at all points under the blade 101 . It will be appreciated that the greater the surface area present on the arm, such as 404 or 1104 , the more potential there is for ice build-up on the arm. Thus, it is contemplated by the disclosure to have an arm 1104 that may have a small surface area as illustrated in FIG. 11 b thereby creating a larger pass through portion 525 , or an arm 404 that may have a large surface area as illustrated in FIG. 5 thereby creating a smaller pass through area 525 . In the embodiment in FIG. 11 b , the arm 1104 is relatively petite in comparison to the hub 1106 . The petiteness of the arm 1104 may allow any ice that has adhered to the material that comprises the arm 1104 to easily break off as the arm 1104 rotates, thereby continuing to permit ice shavings to pass over the arm and through the pass through portion 525 .
A potential advantage of the pass through portion 525 is the ability for the ice shavings to move freely without substantial sticking, adhering, freezing to the arm of the blade holder or otherwise clogging up the machine. Allowing free movement of the ice shavings prevents clogging and freezing problems. The surface of the arms 404 may be textured or coated for decreasing icing problems. The arms 404 may further comprise a paddle portion 528 that, together with the arm structure, may help to control the movement of the ice shavings within the machine. The arms 404 may further comprise a fastening structure 410 , which may include threaded openings, that may be configured to accommodate fasteners therein to attach the blade 101 to the blade holder 301 to form the assembly 310 . Additionally, as can be seen in FIGS. 11 and 11 a , the arms 1104 of blade holder 1110 may be curved as they radiate out from the central hub 1106 . The curvature of the arms 1104 may function and work to reduce the accumulation of ice shavings on the arm 1104 . It will be appreciated that the radius of curvature of one or more of the plurality of arms 1104 may provide a for a greater or lesser reduction of the accumulation of ice shavings on that arm 1104 .
Still further, it will be appreciated that the disclosure contemplates an embodiment wherein the arm may have a very large surface area, such that there is a very little pass through portion or substantially no pass through portion at all. In such an embodiment, substantially the entire arm operates and acts as a paddle to help move or push the shaved ice into the conduit and out of the spout assembly as the blade holder rotates.
FIG. 6 illustrates a schematic view of a blade 101 consistent with the principles disclosed herein. A blade 101 may be generally circular in shape and be configured to rotate about an axis that runs geometrically normal to a top surface 170 of the blade 101 and passes through the center point of the circular blade 101 . However, it will be appreciated that the blade 101 may be another geometric shape, besides circular, without departing from the scope of the disclosure. The blade 101 , may be generally planer, substantially flat and slotted with a plurality of slots or openings 151 .
As illustrated in FIGS. 6 , and 13 - 15 b , there may be a significant number, perhaps hundreds, of slots or openings 151 . Each slot or opening 151 may have an adjacent cutting edge 150 that may be slightly bent upwards toward the direction of the incoming ice block. In FIGS. 15 a and 15 b , which illustrate a side view and a side cross-sectional view of an embodiment of a blade in accordance with the principles of the disclosure, the cutting edge 150 is illustrated as pointing downward with respect to the page. However, it will be appreciated that the ice block may be forced into the cutting edge or blade 150 as described herein. Thus, the blade 101 illustrated in FIGS. 15 a and 15 b may be oriented with respect to the ice block, such that the cutting edge or blade 150 is positioned to cut into the ice block.
The blade 101 may be made of high quality stainless steel to maximize the blade life and reduce corrosion. Other non-corrosive high strength materials may also be used in place of stainless steel without departing from the scope of the disclosure. The blade 101 may be affixed to the blade holder 301 to form the blade assembly 310 such that the assembly can be rotated by a drive motor or other mechanical drive mechanism to provide more consistent ice shavings. For example, a hand crank or other mechanical drive mechanism may be used to rotate or drive the blade assembly without departing from the scope of the disclosure. While in use, whether through a drive motor or other mechanical drive mechanism, the ice shavings fall through the blade 101 by way of the slots 151 and into a collection area where the shavings are moved through a conduit toward the spout 105 and are then available to be dispensed as desired into a container. Once a sufficient quantity of ice shavings are collected in a container, flavoring may be added as desired.
The blade 101 may comprise a cutting portion 610 , which may include the slots or openings 151 and the cutting edges 150 , and a fastening portion 611 . The fastening portion 611 may comprise radially placed attachment points 615 . One or more of the attachment points 615 may be located around the perimeter of the blade 101 . The attachment points 615 may be any structure that facilitates the attachment of the blade 101 to the blade holder 301 and may correspond with the fastening or attachment structure 410 . In an embodiment, the attachment points 615 may be openings or holes that fasteners pass though and into the fastening structure 410 to secure the blade 101 to the blade holder 301 . However, it will be appreciated that other fastening mechanisms may also be used without departing from the scope of the disclosure. For example, threaded inserts and fasteners, screw fasteners, key and keyhole fasteners, post or prong style snap fasteners, mechanical pins, clips or hooks, anchors, bolts, clamps, locknuts, rivets, screws and washer assemblies, or other fasteners known or that may be become known in the future may be used to attach or connect the blade 101 to the blade holder 301 without departing from the scope of the disclosure.
As can be seen in FIGS. 13-15 b , an embodiment of a blade 101 can be seen that illustrates the adjacent placement of the raised cutting surfaces 150 relative to the slot or openings 151 . FIG. 14 shows a detailed view of a portion of an embodiment of a blade 101 of FIG. 13 . It should be noted that the ice shaving blade 101 may be made of many different and various configurations as far as the cutting surfaces 150 and slot 151 patterns are concerned. For example, FIGS. 16 a , 16 b , and 16 c illustrate various embodiments of a blade 101 and examples of patterns created by the cutting surfaces 150 and slots or openings 151 , which may be utilized by the disclosure.
It will be appreciated that a ratio of the surface area of the material from which the blade 101 is manufactured to the slot or opening area may be tailored or predetermined for desired shaved ice output and machine functionality. For example, the ratio may be about 25% material to about 75% opening, or the ratio may be inverted, such that there is about 75% material to about 25% opening. It will be appreciated that any ratio falling within the ranges given above are meant to fall within the scope of the disclosure, for example, the ratio may be 40% material to about 60% openings or about 60% material to about 40% openings.
An embodiment may have a blade 101 that corresponds to a blade holder 301 in which the blade 101 has more attachment points 615 than the blade holder 301 has arms 404 . An embodiment may comprise a blade holder 301 having the same number of arms 404 as the blade 101 has attachment points 615 . In certain embodiments, the blade 101 may be configured such that it flexes during use. Accordingly, in such embodiments the portions of the blade 101 that are adjacent to the arms 404 of the blade holder 301 may be more rigid than portions of the blade 101 that are further away from the support arms 404 of the blade holder 301 . Consequently, the latter, less supported portions of the blade 101 may flex away from the block of ice during use and thus experience less wear and tear. Accordingly, it may be advantageous to rotate the blade 101 relative to the blade holder 301 (and affix the blade 101 to the blade holder 301 in an alternate position) thereby distributing the wear and tear across the whole blade surface, thereby more evenly wearing the cutting surfaces 150 of the blade 101 resulting in longer blade life.
FIG. 7 illustrates the feature of a blade 701 being shifted or rotated with respect to the blade holder 710 in order to prolong the life of the blade 701 . As can be seen in the figure, the blade holder 710 may comprise a plurality of arms 704 , for example, three arms 704 , and is shown being shifted or rotated in dashed lines relative to the blade 701 in order to prolong the usable life of the blade cutting surfaces. More specifically, the arms 704 a may be positioned in position “A” in the figure, which position represents a first assembled position of the blade assembly 700 . The arms 704 b may be positioned in position “B” in the figure, which represents a second assembled position of the blade assembly 700 . As a user determines that the blade 701 is performing in an unsatisfactory manner, the blade 701 can be rotated relative to the blade holder 710 to improve function. The blade 701 may be rotated incrementally one attachment point 706 at a time or may be rotated by a plurality of attachment points 706 in order to utilize a different part of the blade cutting surfaces that have not been used as much as other portions of the blade to extend the life and usefulness of the blade as long as possible.
FIGS. 8 and 9 illustrate the feature of a tensioned blade 801 in a blade assembly 800 . In order to reduce the accumulation of unwanted ice, or ice build-up, on the blade 801 , the blade 801 may be tensioned during the assembly of the blade assembly 800 . As can be seen schematically in FIG. 8 , the blade 801 a may be relatively planer prior to assembly while it is in an untensioned state. The blade holder 810 may be configured with a distance between the mounting holes 815 on the blade holder arms 804 that is less than the distance between corresponding attachment points 816 of the blade 801 .
It will be appreciated that a radial measurement D 1 (illustrated in FIG. 9 and FIG. 11 a ) from a center of rotation of the blade holder 301 (depicted as dashed line R-R in FIG. 9 ), which center of rotation R-R may be the center of the hub 406 (see FIG. 9 and FIG. 11 a ), to the center of the attachment structure 410 of each of the plurality of arms 404 is less than a radial measurement D 2 (illustrated in FIG. 6 ) from a center of rotation R 2 of the blade 101 to the attachment points (such as 615 of FIG. 6 ) of the blade 101 . The radial measurement D 1 may be between a range of about two inches to about eight inches, or may be between about three inches to about seven inches, or may be between about four inches to about six inches, or may be about five inches. It will also be appreciated that distances or lengths of the radial measurements D 1 may be modified depending upon the size of the blade 101 and safety cover 102 to be used with the machine 100 . It will be appreciated that the distance or length of a diameter D 3 of the blade holder 1110 may be approximately twice the length or distance of the radial measurement D 1 , such that the diameter may be between about four inches to about sixteen inches, or may be between about six inches to about fourteen inches, or may be between about eight inches to about twelve inches, or may be about ten inches. Due to the above mechanical properties and physical relationships, and as shown by the blade 801 b in FIG. 8 , the blade 801 will be placed in tension as and when it is attached to the blade holder 810 . As illustrated in FIG. 9 , the blade 801 is in a tensioned state when it is attached to the blade holder 810 .
Referring briefly now to FIGS. 11 a and 11 b , the fastening or attachment structure 1110 of the blade holder 1101 may extend upwardly from the arm 1104 . It will be appreciated that an angle may be formed between the arm 1104 and the attachment structure 1110 at an angle that is substantially normal to the plane in which the arm 1104 generally lies, such that the attachment structure 1110 may be aligned with the attachment points, such as 706 , of the blade, such as 701 , so that a fastener or other mechanical closure may secure the blade to the blade holder 1101 to thereby form the blade assembly. The attachment structure 1110 may comprise a height H 1 . The height H 1 may be about 0.500 inch to about 3.0 inches, or may be about 1.0 inch to about 2.0 inches, or may be about 1.50 inches.
It will be appreciated that the hub 1106 also comprise a height H 2 , which may have a value that is equal to or larger than the height H 1 of the attachment structure 1110 . Thus, for example, the height H 2 may be about 0.500 inch to about 3.0 inches, or may be about 1.0 inch to about 2.0 inches, or may be about 1.50 inches, when the height H 2 of the hub 1106 is about equal to the height H 1 of the attachment structure 1110 . The height H 2 of the hub 1106 may also be about 0.650 inches to about 3.150 inches, or may be about 1.150 inches to about 2.150 inches, or may be about 1.650 inches, when the height H 2 is larger than the height H 1 . A ratio of the height H 2 of the hub 1106 to the height H 1 of the attachment structure 1110 may be about 1.0 to about 1.5 or may be about 1.1 to about 1.3. The difference in height values, or lack thereof, between H 1 and H 2 may result in a blade that can flex to a predetermined extent until contacting the hub 1106 . For example, when the height H 1 is substantially equal to the height H 2 , the blade may be able to flex to a greater degree than when H 2 is larger than H 1 .
Referring now to FIG. 10 , the figure illustrates the feature of a flexible blade during use. In the figure it can be seen that as a block of ice 1005 is pushed into the spinning or rotating blade 1001 , the blade flexes a distance represented in the figure as distance “F.” In the figure, the ice block positioned and labeled at 1005 a (and drawn in a solid line) represents an unloaded condition and position. As a load is applied to the ice block 1005 a by an ice feeder 103 (illustrated best in FIGS. 1-3 ), the blade 1001 a flexes to the blade positioned and labeled at 1001 b (and drawn in dashed lines), which shows a loaded and flexed condition. The loads applied by the ice feeder 103 may range from the weight of the ice block itself to a considerable load of about 180 to about 220 lbs. of pressure or more (for example, 250 lbs. of pressure). Variables that can help determine the load to be applied may be such things as: the blade design, the blade material, the shaved ice rate, the limitation of ice feeder power, environmental conditions, the rotation rate of the blade and other factors.
The hub may comprise a support structure 1009 that mechanically communicates and interacts with the blade to control the amount of flex of the blade as a load is placed on the blade, such that the blade may be loaded evenly. The flex of the blade may be limited by the blade support structure 1009 , which may be part of the hub or other structure, on the blade holder 1010 to prevent damage to the blade 1001 . It will be appreciated that the support structure 1009 may comprise a substantially flat surface or may comprise a curved surface without departing from the scope of the disclosure. It will also be understood that the release of the load on the blade 1001 may allow the blade to move back into its original, unloaded position. When the load is released, the blade moves and experiences a “spring action,” such that any built-up ice may be removed from the cutting surfaces of the blade 1001 as the blade springs back into its original, unloaded position.
It will be appreciated that the disclosure contemplates an embodiment in which the blade may be attached to the blade holder without being in tension, such that the blade does not flex. In such an embodiment, the blade may be substantially static with respect to the blade holder and hub.
FIG. 17 illustrates a tool for safely clearing blockages within an ice block shaving machine. A clearing tool 1600 may be included in a system comprising an ice shaving machine having a blade assembly.
It will be appreciated from the detailed description that it may be desirable to provide a machine for shaving a block of ice that produces light, fluffy, finely textured shaved ice, or a powdery snow-like textured shaved ice product. When shaving ice, blocks of ice provide for a more consistent, powdery snow-like texture than cubed ice, which tends to produce a grainier shaved ice product. Flavoring may then be dispensed onto the powdery snow-like shaved ice, thereby providing a confectionery product for human consumption. Block ice provides several advantages for making shaved ice, such as consistency in the outputted shaved ice product, and the volume of outputted product between ice refills.
Therefore, it is a potential feature of this disclosure to provide a machine for shaving a block of ice that produces light, fluffy, finely textured shaved ice and dispensing the shaved ice into a receiver or a container while maintaining safety of operation and efficiency of operation, such that one or more flavorings may be dispensed on the received shaved ice.
It is a further potential feature of this disclosure to provide a machine for shaving block ice into a snow-like texture, or a light, fluffy, finely textured shaved ice. Blocks of ice produce more even consistency and texture that is more like a powdery snow. The structures of the devices described and used herein above have been adapted for use with blocks of ice. Certain adaptations and improvements have been developed to handle the block ice form.
Another potential feature of this disclosure is to provide a machine for shaving ice and which provides a flavoring dispensing mechanism that permits the convenient selection of flavors. A further potential feature of this disclosure is to provide a machine for shaving ice into a confectionery and which is adapted to provide high volume shaved ice production.
It is a further potential feature of this disclosure to provide a machine for shaving ice that provides enhanced shaving speed control.
Another potential feature of this disclosure is to provide a machine for shaving ice that has an improved blade design.
A further potential feature of this disclosure is to provide a machine for shaving ice that has improved “snow” dispensing.
A further potential feature of the disclosure is to provide a machine and blade assembly for shaving ice that produces light, fluffy, finely textured shaved ice.
It is another potential feature of the disclosure to provide a machine and blade assembly for consistently producing high quality shaved ice even as the block of ice begins to warm and change consistency.
It is another potential feature of the disclosure to provide a machine and blade assembly for shaving ice without taking into account the skill of the worker to produce high quality shaved ice products, wherein the machine and the blade assembly does substantially all of the work necessary to provide a high quality shaved ice product, such that the ability and skill of the worker is not a paramount consideration.
It is to be understood that the above-described embodiments are merely illustrative of numerous and varied other embodiments, which may constitute applications of the principles of the disclosure. Such other embodiments may be readily devised by those skilled in the art without departing from the spirit or scope of the disclosure and it is the inventor's intent that these alternative embodiments be deemed as within the scope of the disclosure.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the disclosure and the disclosure is intended to cover such modifications and arrangements. Thus, while the disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein. | The disclosure pertains generally to shave ice confection machines and processes, and more particularly to a block ice shaving apparatus, system and method whereby an improved blade and blade assembly produce more consistent output with increase machine life. | 5 |
STATEMENT AS TO RIGHTS
This invention was made with government support under grant NS-28711 awarded by the National Institute of Health. The Government has certain rights in this invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of Ser. No. 08/131,887 filed Oct. 5, 1993 now U.S. Pat. No 5,457,207.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vesamicol derivatives that have anticholinergic properties.
2. Description of the Related Art
Cholinergic neurotransmission is comprised of several functional units. These include: 1) sequestration, by presynaptic cholinergic terminals, of choline, the precursor for the synthesis of acetylcholine (ACh); 2) the synthesis of ACh catalyzed by choline acetyltransferase (ChAT); 3) the storage of ACh in synaptic vesicles; 4) release of neurotransmitter into the synapse in response to a stimulus; and 5) degradation of ACh within the synaptic cleft, mediated by acetylcholinesterase (AChE), to regenerate choline. The latter is subsequently recycled. Given the multivariate nature of this system, regulation of cholinergic function may be accomplished in multiple ways. The synthesis of ACh takes place in the cytoplasm. However, ACh is subsequently stored in special organelles called synaptic vesicles. In response to a stimulus, these vesicles fuse with the presynaptic membrane and release their contents into the synapse. Neurotransmitter is characteristically released in discrete amounts or quanta. Therefore, the synaptic vesicle largely defines the unit of ACh release. The release of neurotransmitter is in turn inextricably linked to its storage. Consequently, interference with storage mechanisms provides a means of modulating the release of acetylcholine and thereby modulating cholinergic function.
The lipophilic amino alcohol 2-(4-phenylpiperidino)cyclohexanol (1, vesamicol, AH 5183) induces respiratory paralysis, spasms and death in laboratory animals (Brittain et al, 1969). The pharmacological activity of vesamicol is attributed to its ability to block cholinergic neurotransmission. The latter process is accomplished by the binding of vesamicol to a unique site, the vesamicol receptor, on the cholinergic synaptic vesicle. The vesamicol receptor is functionally linked to the vesicular ACh transporter (Marien et al., 1991), a protein complex which transports ACh from the cytoplasm into the vesicle. Occupancy of the vesamicol receptor by vesamicol or its analogs blocks the storage and subsequent release of ACh, thereby effectively shutting down cholinergic neurotransmission (for review, see Marshall & Parsons, 1987; Parsons et at., 1993). Vesamicol selectively inhibits the storage and release of neurotransmitter without directly affecting the synthesis of this neurotransmitter. The foregoing observations suggest that selective blockade of the vesamicol receptor may provide a means of modulating cholinergic function in animals.
In spite of its potency as an anticholinergic, vesamicol exhibits α-adrenoceptor activity at higher doses. The poor selectivity of this compound limits its use as a selective anticholinergic. Although Rogers et al. (1989) expressed a need for more potent and selective analogs, they failed to suggest methods for increasing potency. Previous studies by Rogers et al. (1989) have shown that 2-aminoethanol fragment of vesamicol is essential for molecular recognition at the vesamicol receptor. In addition, these authors showed that potent VR ligands could be obtained by substitution at the C4-carbon of vesamicol and by ring fusion on the cyclohexyl fragment of vesamicol. In a subsequent study, Efange et al. (1991) reported the synthesis of acyclic vesamicol analogs represented by HBrPP (2a)(FIG. 1). Although 2a lacks the cyclohexyl moiety found in vesamicol, the former was nevertheless found to be equipotent with vesamicol. The latter observation was attributed to the ability of this acyclic analog to adopt a conformation similar to that found in the fused analog ABV (2b), a potent VR ligand. Further exploration of the structure-activity relationships of vesamicol receptor ligands has yielded trozamicol, 3, (Efange et al., 1993), the parent structure for a new class of vesamicol receptor ligands. Although trozamicol is a poor ligand for vesamicol receptor, N-benzylation of trozamicol yields potent ligands such as MIBT, 4, (Efange et al., 1993). In the present study we disclose a new approach to the development of potent vesamicol receptor ligands for modulating presynaptic cholinergic function.
The vesamicol structure may be divided into three major fragments: the cyclohexyl (fragment A), piperidyl (fragment B), and phenyl (fragment C) moieties. In their original investigation, Rogers et al. (1989) carried out extensive modification of all three fragments with varying results. In general, single-point modifications in fragment B or C were found to yield analogs of slightly lower or comparable potency relative to vesamicol. On the other hand, those analogs which represented drastic structural alterations of the piperidyl and phenyl moieties (fragments B and C) were found to be inactive. For example, chlorovesamicol (1b) and nitrovesamicol (1c) and the piperazine-containing analogs 5a-c were between two and eight times less potent than vesamicol. However, the tetrahydroisoquinoline analog 6a was found to be 125 times less active than vesamicol. In addition, the spirofused compound 6b and other analogs (e.g., 7a and 7b) which incorporate fragments B and C in a complex molecule were also found to be inactive. These results clearly suggested that drastic structural modification of fragments B and C would not be fruitful.
The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is "prior art" with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
SUMMARY OF THE INVENTION
In our search for more potent and selective vesamicol analogs, we postulated that a complex amine-containing molecule can successfully replace fragments B and C as long as the following conditions are fulfilled: a) the elements of fragments B and C are contained within this complex molecule; and b) fragment B is constrained in an orthogonal or near-orthogonal orientation relative to fragment C. The simplest structures which fulfill both requirements are spirofused piperidines. Representative compounds from three classes of these spirofused piperidines, spiro[indene-1(1H),4'-piperidine](compound 8), 2,3-dihydrospiro[indene-1,4'-piperidine](compound 9) and spiro[naphthalene-1(2H),4'-piperidine] (compound 10) (FIG. 2), were designed, synthesized and tested in vitro for binding to the vesamicol receptor. Representative compounds from this group were then tested for anticholinergic activity in rats and mice. Henceforth, we will refer to this class of vesamicol receptor ligands as SPIROVESAMICOLS.
These spirovesamicols have relatively poor affinity to human sigma receptors while binding well to vesamicol receptors. This makes the spirovesamicol excellent cholinergic probes. These compounds may be radiolabeled and used as reliable targets for radiotracer development. They may be used as agents to detect Alzheimer's Disease. Additionally, since the compounds of the invention are anticholinergics, they may be used where anticholinergics are desired, such as in pesticides or muscle relaxants. The radiolabel may be a transition metal or any acceptable tag which will make the compound detectable outside the brain. Finally, these new agents may be used for therapeutic applications which require a down regulation of cholinergic function.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
FIGS. 1-10 shows vesamicol and vesamicol analogs;
FIGS. 11-16 shows Scheme 1, the synthesis of spirovesamicols;
FIGS. 17-19 shows Scheme 2, the synthesis of brominated spirovesamicols;
FIGS. 20-32 shows spirovesamicols of the invention; and
FIG. 5 shows the potency of vesamicol analogs at human sigma receptors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Chemistry
The target compounds were synthesized in moderate yields as described in the Experimental section (Schemes 1 and 2). The assignment of structure for compounds 20a-c is based on previous work on nonsymmetrical bipiperidyls (Efange et al., 1993).
Pharmacological Studies in Mice
In vivo anticholinergic activity was evaluated in Swiss Webster mice. Blockade of cholinergic neurotransmission (or anticholinergic activity) was manifested in a rapidly developing respiratory distress, spasms and paralysis. At lethal doses these symptoms were followed by death within 10-20 min. As evident in Tables 1 and 2, the representative compounds tested were lethal at doses as low as 10 umol/Kg. These data clearly demonstrate that these compounds exhibit anticholinergic activity in vivo.
Vesamicol Receptor Binding
Vesamicol receptor binding was performed according to methods published earlier (Kaufman et al., 1988) with the following modifications: higher concentrations of [ 3 H]vesamicol (approx. 5 nM) were used to compensate for the lower receptor concentration employed; 2) the assay mixtures were equilibrated for 24 h. Under the conditions of this assay, the dissociation constant (k d ) for (-)-vesamicol was determined to be 1.0 nM.
The relative potency of spirovesamicols is given on Table 3. In contrast to earlier observations by Rogers et at., we note that replacement of the phenylpiperidyl moiety of vesamicol with spiro[1H-indene-1,4'piperidine] yields several potent compounds. In fact all analogs tested, 11a-d and 11f, are 2 to 10 times more potent than vesamicol. Since the values given here are for the racemates, it is expected that the active enantiomers would be at least twice as active as these racemates. Therefore many of these compounds may be up to twenty times more potent than vesamicol. The incorporation of a bromine atom into the indene structure was generally found to increase or maintain potency. However, the presence of bromine at the C6 position (compound 17) was unfavorable as indicated by the slight reduction in potency (11a vs 17). In contrast, substitution at C2 resulted in 20-fold increase in potency (11a vs 14), suggesting significant bulk tolerance at this position.
Of the four analogs of compound 10 tested, three are less potent than vesamicol. While this observation would appear to suggest that the spiro[naphthalene-1,4'-piperidine] moiety is unsuitable, one analog, 13d, is at least ten times more potent than (-)-vesamicol. In fact 13d is one of the most active spirovesamicols. These results suggest that spirofused nitrogen-containing heterocyles may be used to replace the 4-phenylpiperidyl fragment of vesamicol to develop potent vesamicol ligands for modulating cholinergic transmission.
Experimental
General Section
Synthetic intermediates were purchased from Aldrich, Inc. (Milwaukee, Wis.) and were used as received. Solvents were distilled immediately prior to use. Commercially available reagents were used without subsequent purification.
All air-sensitive reactions were carried out under nitrogen. Standard handling techniques for air-sensitive materials were employed throughout this study. Melting points were determined on a Mel-Temp melting point apparatus and are uncorrected. The specific rotation was determined on an automatic polarimeter (Autopol III, Rudolph Research, Flanders, N.J.). 1 H NMR spectra were recorded on an IBM-Brucker spectrometer at 200 MHz. NMR spectra are referenced to the deuterium lock frequency of the spectrometer. Under these conditions, the chemical shifts (in ppm) of residual solvent in the 1 H NMR spectra were found to be as follows: CHCl 3 , 7.26; DMSO, 2.56; HOD, 4.81. The following abbreviations are used to describe peak patterns when appropriate: br=broad, s=singlet, d=doublet, t=triplet, q=quartet, m=multiplet. Both low- and high-resolution MS were performed on an AEI MS-30 instrument. Elemental analyses were performed by Atlantic Microlab, Inc., Norcross, Ga., and are provided in Table 4. Unless otherwise indicated, these values are within ±0.4% of the theoretical.
Column chromatography was performed using "Baker Analyzed" silica gel (60-200 mesh). Preparative chromatography was performed on either a Harrison Research Chromatotron using Merck 60 PF 254 silica gel or a preparative HPLC (Rainin Instrument Co.) using a 41.1 mm ID Dynamax silica gel column (at a solvent delivery rate of 80 ml/min.). Enantiomeric purity was determined by HPLC with a Chiralcel OD column (isopropyl alcohol: hexane: Et 3 N, 10:89:1; flow rate 1 ml/min.). Analytical TLC was performed on Analtech glass TLC plates coated with silica gel GHLF and were visualized with UV light and/or methanolic iodine. All target compounds were checked for purity by HPLC (silica gel, 10-20% isopropyl alcohol-hexanes, trace Et 3 N).
Procedure A
1'-(2-Hydroxycylohex-1-yl)spiro[1H-indene-1,4'-piperidine]Hydrochloride (11a)
Spiro[1H-indene-1,4'-piperidine]hydrochloride was prepared by the method described earlier by Evans et al. (1992). A mixture of commercially available cyclohexene oxide (0.22 g, 2.24 mmol) and spiro[1H-indene-1,4'-piperidine]hydrochloride in EtOH (20 mL) and triethylamine (5 mL) was refluxed for 21 h, cooled to room temperature and concentrated in vacuo. The residue was dissolved in a min volume of CH 2 Cl 2 and the solution was applied onto a short column of silica gel which was subsequently eluted with acetone(20):hexanes(79):Et 3 N(1). The eluent was concentrated in vacuo to yield a dark red syrup (0.35 g, 55%) which was judged by tlc to be greater than 95% pure. The syrup was dissolved in MeOH, and cooled in an icebath. Dry HCl gas was then bubbled through this solution, thereby converting the free base to the corresponding hydrochloride. The solvent was removed in vacuo to yield a solid which was recrystallized from isopropyl alcohol to provide a light tan solid; mp 280°-283° C.; 1 H NMR (CDCl 3 ) δ1.20-2.29 (m, 12, piperidyl+eychohexyl), 2,74 (d,2, piperidyl α-H, J=5.6 Hz), 2.95 (d,2,piperidyl) 3.45 (m, 1, cyclohexyl CH 2 C HNCHOH), 3.70 (m, 1, cyclohexyl CH 2 CHNC HOH), 6.72 (d, 1, indenyl C2-H, J=5.7 Hz), 6.82 (1, d, indenyl C3-H, J=5.7 Hz), 7.16-7.39 (m, 5, aryl). Anal. (C 19 H 25 NO.HCl)
Procedure B
1'-(2-Hydroxy-1,2,3,4-tetrahydronaphth-3-yl)-spiro[1H-indene-1,4'-piperidine]Hydrochloride (11b)
A biphasic mixture of the bromohydrin (1.14 g, 5.0 mmol) in 2M aq. NaOH (100mL) and CHCl 3 (100 mL) was refluxed for 2.5 h. TLC (silica gel; 50% hexane-CH 2 Cl 2 ) confirmed that formation of the epoxide was complete. The mixture was cooled to room temperature and the two layers were separated. The aq. phase was re-extracted with CHCl 3 (2×30 mL) and discarded. The organic extracts were combined, dried over anhydrous Na 2 SO 4 and concentrated under reduced pressure to yield the crude epoxide as a pale yellow syrup which was redissolved in EtOH (30 mL) and Et 3 N (2 mL). Spiro[1H-indene-1,4'-piperidine]hydrochloride (1.11 g, 5.0 mmol) was added to this solution, and the resulting mixture was refluxed overnight. After 17 h, heating was stopped. The mixture was cooled to room temperature and concentrated to a residue in vacuo. The residue was dissolved in CH 2 Cl 2 (50 mL) and the solution was washed with satd aq. NaHCO 3 (30 mL). The aqueous extract was washed with CH 2 Cl 2 (30 mL) and discarded. The organic extracts were combined, dried over anhydrous Na 2 SO 4 and concentrated to a residue. The latter was dissolved in a minimum volume of CH 2 Cl 2 and applied to a short column of silica gel which was subsequently eluted with 25% acetone-hexane. Concentration of the eluent yielded the product (0.91 g, 55%) as a brown syrup. The latter was estimated by tlc (silica gel, acetone(25):hexane (74):Et 3 N (1)) to be greater than 97% pure. The corresponding hydrochloride was prepared in MeOH as outlined for (11a) above, and recrystallized from isopropyl alcohol; mp 254°-257° C.; 1 H NMR (CDCl 3 ) δ1.46 (d, 2, piperidyl β-H eq ., J= 12.8 Hz), 2.17 (m, 2, piperidyl β-H ax .), 2.86-3.49 (m, 8, tetrahydronaphthyl C1-H, C3-H, C4-H & piperidyl α-H ax .,eq.), 3.93-4.20 (m, 3, piperidyl α-H eq & C HOH), 6.79 (d, 1, indenyl C2-H, J=5.6 Hz), 6.90 (d, 1, indenyl C3-H, J=5.7 Hz), 7.03-7.42 (m, 8, aryl).
Procedure C
Preparation of 1'-(1-butoxycarbonyl,3-Hydroxypiperidin-4-yl)-spiro[1H-indene-1,4'-piperidine](19a) and 1'-(1-butoxycarbonyl-4-Hydroxypiperidin-3-yl)-spiro[1H-indene-1,4'-piperidine](20a)
A solution of 1,2,3,6-tetrahydropyridine in CH 2 Cl 2 (10 mL) was added to a stirring solution of di-tert-butyldicarbonate in CH 2 Cl 2 (40 mL). The resulting mixture was treated with Et 3 N (1 mL) and stirred overnight. After 30 h, the reaction mixture was concentrated to provide a clear colorless liquid which was redissolved in THF (100 mL). To this solution was added N-bromosuccinimide (4.45 g, 25.0 mmol) and water (25 mL). The resulting biphasic mixture was stirred at room temperature for 23 h, diluted with water (40 mL) and extracted with CH 2 Cl 2 (2×50 mL). The combined organic extracts were dried over anhyd Na 2 SO 4 and concentrated under reduced pressure to a syrup. The latter was triturated with hot hexane and cooled to cause precipitation of succinimide. The precipitate was removed by filtration and discarded. The filtrate was concentrated to provide a mixture of the isomeric bromohydrins as a yellow syrup (6.8 g, 98%). A fraction of this syrup (3.64 g, 13.0 mmol) was refluxed for 2 h in a biphasic mixture of CHCl 3 (100 mL) and 2.5M aq. NaOH (100 mL). The mixture was allowed to cool to room temperature and the layers were separated. The aq. layer was re-extracted with CHCl 3 (2×30 mL) and discarded. The combined organic extracts were dried over anhyd Na 2 SO 4 and concentrated to yield N-tert-butoxycarbonyl-1,2,3,6-tetrahydropyridine oxide (2.72 g) as an orange liquid. A mixture of the crude epoxide (2.72 g) and 8 (2.22 g, 10.0 mmol) in EtOH (60 mL) and Et 3 N (15 mL) was refluxed for 24 h, cooled and concentrated to a residue. The latter was partitioned between CH 2 Cl 2 (50 mL) and water (40 mL). Following separation of the layers, the aq. phase was re-extracted with CH 2 Cl 2 (50 mL). The organic extracts were combined, dried over anhyd. Na 2 SO 4 , cone to a minimum volume and passed through a short column of silica gel (eluting with 20% acetone(20):hexane(79):Et 3 N(1)). Concentration of the eluent provided a red syrup which was subjected to preparative HPLC (5:94:1 i-PrOH/hexane/Et 3 N; flow rate, 80 mL/min). Concentration of the more mobile fraction yielded 19a (0.61 g, 16%) as a syrup. () 1 H NMR (CDCl 3 ) δ1.45 (broad s, 9, (CH 3 )--C), 1.70-1.90 (m, 2, piperidyl), 2.01 (td, 1, piperidyl), 2.11-2.28 (m, 2, piperidyl), 2.38-2.70 (m, 2, piperidyl), 2.76-3.00 (m, 3, piperidyl), 3.47 (m, 1, piperidyl), 3.67 (m, 1, piperidyl), 3.91-3.40 (m, 2, piperidyl), 4.15 (m, 1, N--C H--CHOH), 4.28 (broad s, 1, HC--OH), 4.45 (broad S, 1,--OH) 6.74 (d, 1, J=6 Hz, ph-CH═C H), 6.80 (d, 1, J=6 Hz, ph-C H═CH--), 7.20-7.39 (m, 4, phenyl). The less mobile fraction, 20a (1.90 g, 49%) was obtained as the major component. 1 H NMR (CDCl 3 ) δ1.52 (m, 11, (CH 3 ) 3 --C, piperidyl), 1.99-2.35 (m, 4, piperidyl), 2.40 (td, 1, piperidyl), 2.61 (td, 1, piperidyl), 2.72-2.82 (m, 3, piperidyl), 2.92 (m, 1, piperidyl), 3.07 (m, 2, piperidyl), 3.63 (m, 1, N--C H--CHOH), 4.13 (broad s, 1, HC--OH), 4.38 (broad s, 1, --OH), 6.74-6.80 (complex dd, 2H, indyl), 7.18-7.41 (m, 4, phenyl). Anal. (C 23 H 32 N 2 O 3 ) C,H,N.
Resolution of 20a
Racemic 20a was resolved on a Chiralcel OD column (20% i-PrOH-hexane) to yield 0.8 g of (+)-20a and 0.8 g of (-)-20a (64% recovery).
(+)-20a:retention time, 14.6 min;[α] D =+38.72° (C=0.02M, MeOH)
(-)-20a:retention time, 20.3 min;[α] D =-38.95° (C=0.02M, MeOH)
(+)-1'-(4-Hydroxypiperidin-3-yl)spiro[1H-indene-1,4'-piperidine]dihydrochloride {(+)-21a}and (-)-1 '-(4-Hydroxypiperidin-3-yl)spiro[1H-indene-1,4'-piperidine]dihydrochloride {(-)-21a}
Solutions of (+)-20a and (-)-20a in EtOAc (20 mL) were cooled down to 0° C. Dry HCl gas was bubbled through these solutions for 30 min with stirring. The stirring was continued for additional 30 min at 0° C. The solutions were concentrated under reduced pressure to yield (+)-21a (0.62 g, 84%) and (-)-21a (0.69 g, 93%), respectively; mp 279°-282 ° C.
Procedure D
1'-(4-Hydroxy1-(2-iodobenzyl) piperidin-3-yl)-spiro[1H-indene-1,4'-piperidine]dihydrochloride (11c)
A mixture of sodium bicarbonate (0.42 g, 5.0 mmol), 2-iodobenzyl chloride (0.23 g, 0.92 mmol) and 1'-(4-hydroxypiperidin-3-yl)spiro[1H-indene-1,4'-piperidine]dihydrochloride (0.30 g, 0.84 mmol) in EtOH (13 mL) and water (6 mL) was refluxed for 23 h. The resulting mixture was cooled and concentrated under reduced pressure. The residue was partitioned between CH 2 Cl 2 (30 mL) and water (25 mL). After separation of the layers, the aq. layer was re-extracted with CH 2 Cl 2 (2×30 mL) and discarded. The combined organic layers were dried over anhyd Na 2 SO 4 and concentrated to a residue which was purified by radial flow chromatography on silica gel (13:86:1 acetone/hexane/triethylamine) to yield 0.13 g (31%) of the free base as a pale yellow syrup. The latter was converted to the corresponding hydrochloride in methanol as described above, and recrystallized from i-PrOH to give a white solid; mp 242°-245° C. The yield was increased to 71% when Procedure E was used. 1 H NMR (CDCl 3 ) δ1.36 (d, 2, piperidyl), 1.66 (dt, 1, piperidyl), 2.04-2.27 (m, 5, piperidyl), 2.57 (t, 1, piperidyl), 2.64 (dt, 1, piperidyl), 2.70-3.52 (m, 5, piperidyl), 3.57-3.62 (m, 3, benzyl,piperidyl), 3.80 (broad s, 1, OH--), 6.73 (d, J=6 Hz, 1, Ph--CH═C H), 6.80 (d, J=6 Hz, 1, Ph--C H═CH), 6.96 (t, J=9 Hz, 1, iodophenyl), 7.21-7.44 (m, 6H, iodophenyl, phenyl), 7.84 (d, 1, J=6 Hz, iodophenyl).
Procedure E
1'-(4-Hydroxy1-(3-iodobenzyl)piperidin-3-yl)-spiro[1H-indene-1,4'-piperidine]dihydrochloride (11d)
A mixture of 21b (0.30 g, 0.84 mmol), 3-iodobenzyl bromide (0.25 g, 0.84 mmol) and K 2 CO 3 (0.4 g, 2.89 mmol) was stirred in DMF (20 mL) at room temperature for 18 h. The reaction mixture was diluted with CH 2 Cl 2 (50 mL) and filtered, diluted with H 2 O (100 mL), the organic layer was separated and the aqueous layer was re-extracted with CH 2 Cl 2 (50 mL). The combined organic extracts were dried over Na 2 SO 4 , concentrated under reduced pressure to obtain a liquid residue. The residue which was purified by passing through a short silica gel column (33% acetone-hexane). The eluent was concentrated under reduced pressure to obtain a yellow syrup (0.29 g, 71%). The free base was converted to the dihydrochloride using methanolic HCl; m.p. 226°-228° C. 1 H NMR (CDCl 3 ) δ1.35 (d, 2, piperidyl), 1.64 (dt, 1, piperidyl), 1.93-2.25 (m, 5, piperidyl), 2.54 (t, 1, piperidyl), 2.66(dt, 1, piperidyl), 2.79-3.10 (m, 5, piperidyl), 3.40-3.56 (m, 3, benzyl,piperidyl), 3.80 (broad s, 1, OH--), 6.72 (d, J=6 Hz, 1, Ph--CH═C H), 6.80 (d, J=6 Hz, 1, Ph--C H═CH), 7.06 (t, J=9 Hz, 1, iodophenyl), 7.20-7.36 (m, 5, iodophenyl, phenyl), 7.58 (d, 1, iodophenyl), 7.69 (s, 1, iodophenyl).
1'-(4-Hydroxy1-(4-iodobenzyl)piperidin-3-yl)-spiro[1H-indene-1,4'-piperidine]dihydrochloride (11e)
Procedure E
Yield, 52%; mp (ether-isopropyl alcohol) 243°-245° C. 1 H NMR (CDCl 3 ) δ1.35 (d, 2, piperidyl), 1.62 (dt, 1, piperidyl), 1.92-2.30 (m, 5, piperidyl), 2.56 l (m, 2, piperidyl), 2.86-3.07 (m, 5, piperidyl), 3.40-3.57 (m, 3, benzyl, piperidyl), 3.81 (broad S, 1,--OH), 6.72 (d, 1, J=6 Hz, Ph--CH═CH--), 6.79 (d, 1, J=6 Hz, Ph--CH═CH--), 7.07 (d, 2, J=8Hz, Iodophenyl), 7.17-7.36 (m, 4, phenyl), 7.64 (d, 2, J=8 Hz, iodophenyl).
1'(4-Hydroxy-1-(2-fluorobenzyl)piperidin-3-yl)-spiro[1H-indene-1,4'-piperidine]dihydrochloride (11f)
Procedure E
Yield, 66%; m.p.(acetone) 126°-128° C. 1 H NMR ((CDCl 3 ) δ1.36 (d, 2, piperidyl), 1.64 (dt, 1, piperidyl), 1.94-2.16(m, 6, piperidyl), 2.62 (t, 1, piperidyl), 2,79-3.13 (m, 5, piperidyl), 3.40-3.56 (m, 3, benzyl piperidyl), 3.80 9 broad s, 1, OH--), 6.75 (d, J=6 Hz, 1, Ph--CH═C H), 6.78 (d, J=6 Hz, 1, Ph--C H═CH), 7.01 (t, J=8 Hz, 2, fluorophenyl), 7.18-7.36 (m, 6, fluorophenyl, phenyl).
1'-Benzyl-2,3-Dihydrospiro[indene-1,4'-piperidine](31)
4-(2-Phenylethyl)pyridine (8.5 g, 46 mmol) and benzyl chloride (11.64 g, 92 mmol) were refluxed in acetone for 48 h. The precipitated 1-benzyl-4-(2-phenylethyl)pyridinium chloride was filtered, washed with acetone and dried in vacuo at 50° C. to obtain 9.35 g (65%) off the white solid. 1-Benzyl-4-(2-phenylethyl)pyridinium chloride (9.0 g, 29.0 mmol) was suspended in MeOH (100 mL) and cooled to 0° C. in an ice bath. NaBH 4 (4.73 g, 207.2 mmol) was added portionwise with vigorous stirring over 40 min. After cooling and stirring for an additional 1 h, the reaction mixture was concentrated under reduced pressure and partitioned between H 2 O (50 mL) and CH 2 Cl 2 (50 mL). The layers were separated, and the aqueous phase was re-extracted with CH 2 Cl 2 (50 mL). The combined CH 2 Cl 2 extracts were dried over Na 2 SO 4 , and concentrated under reduced pressure to provide 7.1 g (91%) of 1-benzyl-4-(2-phenylethyl)-1,2,3,6-tetrahydropyridine as a pale yellow oil. 1 H NMR ((CDCl 3 ) δ2.14 (br s, 2, N--CH 2 --C H 2 --CH ═), 2.27 (t, 2, J=8 Hz, N--C H 2 --CH 2 --), 2.57 (t,2, J=6 Hz, Ph--C H 2 --CH 2 --), 2.73 (m, 2, Ph--CH 2 --C H 2 --), 2.97 (br s, 2, N--C H 2-- CH═), 3.59 (s, 2, Ph-CH 2 --N), 5.41 (m, 1, CH═C--), 7.14-7.38 (m, 10, phenyl). 1-Benzyl-4-(2-phenylethyl)-1,2,3,6-tetrahydropyridine (7.1 g, 25.6 mmol) was refluxed in 85% H 3 PO 4 (50 mL) for 80 h. The reaction mixture was basified with 6N NH 4 OH and extracted with ether (2×100 mL). The ethereal extracts were dried over MgSO 4 and concentrated under reduced pressure to a residue. The crude product was purified by radial flow chromatography on silica (hexane,9:acetone,1) to yield 2.3 g (32%) of 1'-benzyl-2,3-dihydrospiro[indene-1,4'-piperidine] as a straw colored liquid. 1 H NMR (CDCl 3 ) δ1.53 (br d, 2, piperidyl β-H eq .), 1.96 (dt, 2, piperidyl β-H ax ),2.02 (t, 2, Ph--CH 2 --C H 2 --, J=6 Hz, ), 2.20 (dt, 2, piperidyl α-H ax ), 2.90 (m, 4, Ph-C H 2 --CH 2 -- & piperidyl α-H eq ), 3.59 (s, 2, benzyl), 7.14-7.40 (m, 9, phenyl).
2,3-Dihydrospiro[1H-indene-1,4'-piperidine]Hydrochloride (9)
1'-Benzyl-2,3-dihydrospiro[1H-indene-1,4'-piperidine] (0.50 g, 1.80 mmol) was dissolved in dichloroethane (6 mL). The resulting solution was cooled to 0° C. and 1-chloro-ethylchloroformate (0.258 g, 1.80 mmol) was added in one batch. Cooling was continued for 10 min after which the reaction mixture was refluxed for 1 h, cooled to room temperature and concentrated under reduced pressure. The residue was redissolved in MeOH (10 mL) and refluxed for 2 h. The resulting solution was concentrated under reduced pressure to obtain (0.40 g, quant.) of a pale yellow crystalline solid; m.p. 256°-257° C. (lit. 288-290); 1 H NMR (CDCl 3 ): δ1.74 (br d, 2, piperidyl β-NH eq ), 2.10 (td, 2, piperidyl β-H ax ), 2.13 (t, 2, Ph--CH--CH 2 --C H 2 --, J=6 Hz), 2.94 (t, 2, J=6 Hz, Ph--C H 2 --CH 2 --), 3.12-3.38 (m, 4, piperidyl α-H ax ,eq), d=7.19 (br s, 4, phenyl). MS (EI) m/e 187.2 (M + of free base).
2,3-Dihydro-1'-(2-Hydroxycylohex-1-yl)spiro[1H-indene-1,4'-piperidine]Hydrochloride (12a)
Procedure A
Yield, 60%; m.p. 264°-267° C. 1 H NMR (CDCl 3 ) δ1.25 (broad d, 2, eqi.piperidyl(N--CH 2 --C H 2 -)), 1.76-2.94 (m, 15, cyclohexyl, piperidyl), 2.00 (t, 2, J=6 Hz, Ph--CH 2 --C H 2 --), 2.77 (t, 2, J=6 Hz, Ph--C H 2 --CH 2 --), 3.40 (m, 1, C H--OH), 4.17 (broad s, 1, --OH), 7.25 (s, 4, phenyl).
1'-(2-Hydroxy- 1,2,3,4-tetrahydronaphth-3-yl)-2,3-dihydrospiro[1H-indene-1,4'-piperidine]hydrochloride (12b)
Procedure B
Yield, 48%; mp 267°-269° C. 1 H NMR (CDCl 3 ) δ1.86 (br d, 2, piperidyl β-Heq.), 2.04 (td, 2, piperidyl β-Hax), 2.08 (t, 2, J=6 Hz, Ph--CH 2 --C H 2 --), 2.45 (td, 1, piperidyl α-Hax), 2.84 (m, 9, piperidyl αHeq, cyclohexyl, Ph--C H 2 --CH 2 --), 3.33 (dd, 1, eqi. piperidyl(N--C H 2 --CH 2 --)), 3.92 (m, 1, C H--OH), 4.47 (broad s, 1, OH--), 7.15 (s, 4, phenyl(spiro)), 7.32 (m, 5, phenyl).
1'-(1-t-butoxycarbonyl-3-hydroxypiperidin-4-yl)-2,3-dihydrospiro[indene-1,4'-piperidine] (19b) and 1'-(1-t-butoxycarbonyl-4-hydroxypiperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-piperidine] (20b)
Procedure C. 19b
Yield, 14%. 1 H NMR (CDCl 3 ) δ1.45 (s, 9H,t-butyl), 1.56 (m, 2, piperidyl), 1.86 (m, 4, piperidyl), 1.97 (t, J=6 Hz, 2, Ph--CH 2 --C H 2 --), 2.32 (m, 2, piperidyl), 2.55 (m, 3, piperidyl), 2.88 (t, J=6 Hz, 2, Ph--C H 2 --CH 2 --), 3.85 (m, 1, piperidyl), 3.95 (m, 1, piperidyl), 4.22 (br d, 1, piperidyl), 4.40 (br d, 1, piperidyl), 7.17 (s, 4, phenyl).
20b
Yield, 25%; 1 H NMR (CDCl 3 ) δ1.45 (s, 9H, t-butyl), 1.56 (m, 2, piperidyl), 1.74-2.11 (m, 7, Ph--CH 2 --C H 2 --piperidyl), 2.38 (m, 2, piperidyl), 260 (m, 4, piperidyl), 2.89 (t, J=6 Hz, 2, Ph--C H 2 --CH 2 --),3.58 (m, 1, piperidyl), 3.68 (m, 1, piperidyl), 4.13 (m, 1, piperidyl), 4.27 (broad d, 1, piperidyl), 7.18 (s, 4, phenyl).
Resolution of 20b
Racemic 20b (0.6 g, 1.55 mmol) was resolved on Chiralcel OD column (30:70 i-PrOH:hexane (trace Et 3 N)) to yield 0.22 g of (+)-20b and 0.23 g of (-)-20b. (75% recovery). (+)-20b: retention time, 12.5 min;[α]=+28.74° (c=0.02M,MeOH) (-)-20b: retention time, 18.2 min;[α]=+28.87° (c=0.02M,MeOH).
(+)-1'-(4-Hydroxypiperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-indene]hydrochloride {(+)-21b } and (+)-1'-(4-Hydroxypiperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-piperidene]hydrochloride {(-)-21b}
Solutions of (+)- and (-)-20b in EtOAc (20 mL) were cooled down to 0° C. Dry HCl gas was bubbled through these solutions for 30 min. with stirring. The stirring was further continued for additional 30 min. at 0° C. The solutions were concentrated under reduced pressure to yield the corresponding deprotected hydrochlorides, (+)-21b (92%) and (-)-21b (90%); m.p. 280°-283° C.
(dl)-1'-(4-Hydroxypiperidin-3-yl)-2,3-dihydrospiro[indene-1,4-piperidine]dihydrochloride (21b)
Method 2: A mixture of 21a (1.2 g, 3.35 mmol) and 10% Pd-C (0.2 g) in MeOH (50 mL) was hydrogenated for 3 h at 50 psi. The catalyst was filtered and the filtrate was concentrated under reduced pressure to yield an off-white solid (1.12 g, 93%). m.p. 280°-283° C.
1 H NMR δ=1.79 (d, 2, piperidyl), 1.96 (dt, 1, piperidyl), 2.14 (t, J=8 Hz, 2, Ph--CH 2 --C H 2 --), 2.35 (m, 4, piperidyl), 2.95 (t, J=8 Hz, 2, Ph--C H 2 --CH 2 --), 3.10-374 (m, 9, piperidyl), 4.05 (d, 1, piperidyl), 4.28 (dt, 1, piperidyl), 7.11-7.39 (m, 4, phenyl).
1'-(4-Hydroxy1-(2-iodobenzyl)piperidin-3-yl-2,3-dihydrospiro[indene-1,4'-piperidine]dihydrochloride (12c)
Procedure E
Yield, 39%; m.p.(i-PrOH-ether) 246°-249° C.
1 H NMR (CDCl 3 ) δ1.59 (m, 2, piperidyl), 1.80-2.10 (m, 8, piperidyl,indane), 2.31 (t, 1, piperidyl), 2.51 (t, 1, piperidyl), 2.67-3.10 (m, 7, piperidyl,indane), 3.40-3.54 (m, 3, benzyl, piperidyl), 4.05 (broad s, 1, --OH), 6.95 (t, 1, iodophenyl), 7.16-7.30 (m, 5, iodophenyl, phenyl), 7.32 (d, 1, iodophenyl), 7.81 (s, 1, iodophenyl).
1'-(4-Hydroxy-1-(3-iodobenzyl)piperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-piperidine]dihydrochloride (12d)
Procedure E
Yield, 73%; m.p. (i-PrOH-ether) 243-246° C.
1 H NMR (CDCl 3 ) δ1.50 (m, 2, piperidyl), 1.78 (dt, 1, piperidyl), 1.88-2.02 (m, 7, piperidyl,indane), 2.31 (t, 1, piperidyl), 2.54(t, 1, piperidyl), 2.67-3.00(m, 7, piperidyl,indane), 3.40-3.51 (m, 3, benzyl,piperidyl), 3.80 (broad s, 1, --OH), 7.03 (t, J=9 Hz, 1, iodophenyl), 7.14-7.28 (m, 5, iodophenyl, phenyl), 7.57 (d, 1, iodophenyl), 7.66 (s, 1, iodophenyl).
1'-(4-Hydroxy1-(4-iodobenzyl)piperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-piperidine]dihydrochloride (12e)
Procedure E
Yield, 50%: mp (i-PrOH-ether) 248°-249° C. 1 H NMR (CDCl 3 ) δ1.51 (m, 2, piperidyl), 1.67-1.93 (m, 8, piperidyl, indane), 2.35 (t, 1, piperidyl), 2.57 (dt, 1, piperidyl), 2.75-3.04 (m, 7, piperidyl, indane), 3.41-3.54 (m, 3, benzyl, piperidyl), 3.80 (broad s, 1, --OH), 7.06 (d, 2, J=8 Hz, iodophenyl), 7.17-7.35 (m, 4, phenyl), 7.64 (d, J=8 Hz, iodophenyl).
1'-(4-Hydroxy1-(4-fluorobenzyl) piperidin-3-yl)-2,3-dihydrospiro[indene-1,4'-piperidine]oxalate (12f)
Procedure E
Yield, 84%; m.p. (i-PrOH-ether) 129°-131° C.
1 H NMR (CDCl 3 ) δ1.62 (m, 3, piperidyl), 1.78-2.06 (m, 7, piperidyl,indane), 2.37 (t, 1, piperidyl), 2.59 (dt, 1, piperidyl), 2.76-3.05 (m, 7, piperidyl,indane), 3.41-3.58 (m, 3, benzyl,piperidyl), 3.80 (broad s, 1, --OH), 7.01 (t, 2, fluorophenyl J=8 Hz), 7.14-728 (m, 6, fluorophenyl, phenyl).
Procedure F
3,4-Dihydro-1'-(2-Hydroxycyclohex-1-yl)-spiro[naphthalene-1,4'-piperidine]hydrochloride (13a)
A flask containing a mixture of 10 (505 mg, 2.51 mmol) in dichloromethane (2 mL) was maintained at 0° C. while Et 3 Al (1.32 mL, 2.51 mmol)) was added dropwise. The solution was stirred at room temperature for 35 min. The flask was then placed in an ice bath and a solution of cyclohexene oxide (255 mL, 2.51 mmol.) in dichloromethane (75 mL) was added. The resulting mixture was stirred at room temperature for 18 h, while the disappearance of the epoxide was monitored by TLC (silica gel, ethyl acetate/hexanes, 50/50). When the reaction was complete (the solution became white), 5N KOH (2 mL) was added and stirring was prolonged for 2 h. Water (10 mL) was added and the mixture was extracted with dichloromethane (3×20 mL). After extraction, the combined organic extracts were washed with brine, dried (Na 2 SO 4 ) and concentrated. The desired compound, 13a, was obtained as a white crystalline solid (598 mg, 80%); no impurities were observed by TLC (Silica gel, Ethyl acetate/hexanes: 50/50). The hydrochloride was prepared in methanolic HCl and the white solid was recrystallized from 50% ethyl acetate-hexanes; mp 306.6° C.; 1 H-NMR (CDCl 3 ) δ2.24-1.22 (3 m, 16, piperidine+cyclohexanol), 2.46-2.52 (m, 2, Ph--CH 2 ), 2.65-2.79 (m, 4, Ph--CH 2 --C H 2 --C H 2 ), 2.98-3.02 (dt, 1, CHN), 3.42-3.47 (s, 1, C H--OH), 4.18 (s, 1, OH), 7.05-7.26 (m, 3, arom.), 7.45-7.49 (d, 1H, arom. J=7.7 Hz). Anal. (C 20 H 29 NO.HCl) C,H,N.
3,4-Dihydro-1'-(2-hydroxy-1,2,3,4-tetrahydronaphth-3-yl)-spiro[naphthalene-1(2H), 4'-piperidine]hydrochloride (13c)
Crude 1,4-dihydronaphthalene (340 mg, 2.3 mmol), obtained from the corresponding bromohydrin as outlined for 11b above, was reacted with 10 following Procedure F to yield after purification on silica gel (ethyl acetate/hexanes/triethylamine, 50/50/1) a white solid (583 mg, 72%).The hydrochloride was prepared in methanolic HCl and recrystallized from ethyl acetate; mp 274.2° C. 1 H NMR (CDCl 3 ) δ1.23-2.24 (m, 16, piperidine+cyclohexanol), 2.73-2.79 (m, 4, Ph--CH 2 --C H 2 --C H 2 ), 2.85-3.02(dt, 1, CHN), 3.30-3.45 (m, 1, C HOH), 4.18 (s, 1, OH), 7.05-7.26 (m, 7, arom.), 7.48-7.52 (d, 1, arom. J=7.6 Hz). Anal. (C 24 H 29 NO.HCl) C, H, N.
1'-(1-t-butoxycarbonyl-3-hydroxypiperidin-4-yl)-3,4-dihydro-spiro[naphthalene-1(2H),4'-piperidine](19c) and 1'-(1-t-butoxycarbonyl-4-hydroxypiperidin-3-yl)-3,4-dihydro- spiro[naphthalene-1(2H),4'-piperidine] (20c)
A mixture of the hydrochloride of 10 (4.9 g, 20.6 mmol) and 5.8g (21 mmol) of the isomeric bromohydrins derived from 1-t-butoxycarbonyl-1,2,3,6-tetrahydropyridine (see Procedure above) in absolute ethanol (25 mL) and triethylamine (15 mL) was refluxed for 24 h. Since TLC (silica gel, Hexanes/Ethyl acetate: 50/50) failed to show any progress in the reaction, solid potassium carbonate (7.26 g, 52.5 mmol) was added and the mixture was refluxed for four more days. After cooling, the salts were filtered off and the volatiles were removed under reduced pressure. The remaining brown oil was dissolved in ethyl acetate (30 mL) and the organic layer was successively washed with water (2×20 mL) and brine (20 mL), dried (Na 2 SO 4 ) and concentrated. The mixture of 19c and 20c was obtained as an orange oil (6.7 g, 84%). The regioisomers were separated by preparative HPLC on a silica gel column(Hexanes/Isopropanol/Triethylamine: 98/2/0.02) to afford 1.58 g of 19c (retention time, 7 min) and 3.70 g of 20c (retention time, 8 min).
19c
1 H NMR (CDCl 3 ) δ1.45 (s, 9, t-butoxy), 1.58-1.84 (m, 8, NC H 2 --CH 2 ), 1.92-2.25(m, 2, Ar-C H 2 --C H 2 --C H 2 ), 2.35-2.54 (m, 6, C H 2 --C H 2 N(t-BOC--C H 2 ), 2.72-2.78 (m, 4, Ar--C H 2 C H 2 --C H 2 ) 2.87-2.98 (t, 1, CH--N, J=11.8 Hz), 3.38-3.50 (m, 1, C H--OH), 7.05-7.22 (m, 3, arom.), 7.43-7.46 (d, 1, arom. J=7.7 Hz).
20c
1 H NMR (CDCl 3 ) δ1.47 (s, 9, 3 CH 3 ), 2.18-1.57 (2m, 8, 2N-C H 2 --C H 2 ), 2.38-2.30 (dt, 2, C H 2 --CHOH, J=3.6, 13.6), 2.57-2.49 (t, 2, Ar--CH 2 , J=9.9), 2.64-2.58 (d, 2, N--C H 2 --CHN, J=11.9), 2.78-2.75 (m, 4, Ar-CH 2 --C H 2 --CH 2 ), 3.09-2.98 (t, 2; CH 2 --C H 2 --N--tBOC, J=11.2), 3.66-3.54 (dt, 1, CH--N, J=4.6, 10.3), 3.83 (s, 1, C H--OH), 7.21-7.03 (m, 3, arom.), 7.45-7.42 (d, 1, arom. J=7.7 Hz).
Resolution of 20c
Separation of the two enantiomers (+)- and (-)-20c was performed on a 25 cm×10 mm id Chiralcel OD (Hexanes/Isopropanol/Triethylamine: 70/30/0.3)to afford (+)-20c (retention time: 10 min) and (-)-20c (retention time: 18 min) as white crystalline solids; (+)-20c: [α] D =+30.2° (c=1.0, MeOH); (-)-20c: [α] D =-30.9° (c=1.0, MeOH).
1'-(4-Hydroxypiperidin-3-yl)-3,4-dihydrospiro[naphthalene-1(2H),4'-piperidine]dihydrochloride (21c)
HCl gas was bubbled for 30 min through a soln of 20c (800 mg, 2.1 mmol) in EtOAc (10 mL) while the flask was maintained in an ice bath. The resulting solution was subsequently stirred at room temperature for 30 min, and the volatiles were removed under reduced pressure. The white solid thus obtained was recrystallized from 50% isopropyl alcohol-hexanes to provide the hydrochlorides of 21c as a white powder (80%).
Elemental analysis: Calc: C=61.12, H=8.1, N=7.5; Fnd: C=59.96, H=7.95, N=6.86.
1'-(1-(3-Iodobenzyl)-4-hydroxypiperidin-3-yl)-3,4-dihydrospiro[naphthalene-1(2H),4'- piperidine] (13d)
A mixture of 21c and 22c derived from a mixture of 19c and 20c as described above (676 mg, 1.81 mmol), 3-iodobenzylbromide (2.17 mmol, 645 mg), and triethylamine (10 mL) in absolute EtOH (20 mL) was refluxed for 18 h. Volatiles were removed under reduced pressure and the red residue was treated with water. After extraction in dichloromethane (3×30 mL), the combined organic layers were washed with brine, dried over Na 2 SO 4 and concentrated to give a dark red semi-solid residue. Chromatographic purification (silica gel, 50% ethyl acetate-hexanes) afforded 276 mg (30%) of the crude product as a yellow oil. The two regioisomers were separated by HPLC (Silica gel, Hexane/Isopropanol/Triethylamine: 98/2/0.02) and 13d was obtained as a white crystalline solid (166 mg, 18%). Only a trace of the other isomer was recovered. The hydrochloride of 13d was prepared in said methanolic saturated HCl and subsequently recrystallized from 50% i-PrOH-hexanes to provide a white powder; mp 245° C. 1 H NMR ((CDCl 3 ) δ1.59-2.06 (m, 8, 2 N--C H 2 --C H 2 ), 2.41-2.48 (m, 2, Ar--C H 2 --CH 2 ), 2.52-2.62 (m, 2, C H 2 --CHOH), 2.75-2.78 (m, 4, Ar--CH 2 --C H 2 --C H 2 ), 2.83-2.92 (m, 2, C H 2 --CH 2 --CHOH), 3.01-3.06 (d, 2, N--C H 2 --CHN, J=10.0 Hz), 3.38-3.56 (m, 3, Ar--CH 2 --N+CH--N), 3.85 (s, 1, C H--OH), 7.02-7.31 (m, 5, arom.), 7.44-7.48 (d, 1, arom., J=7.8 Hz), 7.58-7.62 (d, 1, arom., J=7.9 Hz), 7.68 (s, 1, arom.).
1'-(1-(2-Iodobenzyl)-4-hydroxypiperidin-3-yl)-3,4-dihydrospiro[naphthalene-1(2H),4'-piperidine] (13c)
A mixture of the dihydrochloride of 21c (250 mg, 0.67 mmol), DMF (10 mL), potassium carbonate (463 mg, 3.35 mmol) and 2-iodobenzyl chloride (1.00 mmol), 254 mg) was stirred at room temperature for 18 h. Water (25 mL) and dichloromethane (2×25 mL) were added and the organic layer was extracted, washed with brine (25 mL), dried (Na 2 SO 4 ) and concentrated. The crude product was purified by chromatography (silica gel, hexanes/ethyl acetate, 50/50) to afford 13c as a yellow oil. The latter was converted to the corresponding hydrochloride in satd HCl/ether and recrystallized twice from 50% i-PrOH-hexanes to yield 0.20g (33%) of 13c; mp 258.8° C. 1 H NMR (CDCl 3 ) δ1.50-2.21 (2 m, 8, 2N--C H 2 --C H 2 ), 2.45-2.57 (m, 2H, Ar--C H 2 --CH 2 , J=10.2 Hz), 2.60-2.76 (m, 2, C H 2 --CHOH), 2.84 (m, 4, Ar--CH 2 --C H 2 --C H 2 ), 2.88-3.00 (t, 2, C H 2 --CH 2 --CHOH, J=11.2 Hz), 3.09-3.13 (d, 2, N--C H 2 --CHN, J=8.7 Hz), 3.50-3.64 (m, 3, Ar--CH 2 --N+CH--N), 3.85 (s, 1, C H--OH), 4.67 (s, 1, OH), 6.96-7.49 (m, 8H, arom.), 7.83-7.87 (d, 1H, arom., J=6.8 Hz).
1'-(1-(4-fluorobenzyl)-4-hydroxypiperidin-3-yl)-3,4-dihydrospiro[naphthalene-1(2H),4'-piperidine] (13f)
Procedure E
Yield, 13%; mp 232.4° C.; 1 H NMR (CDCl 3 ) δ1.50-2.10 (m, 8, 2 N--C H 2 --C H 2 ), 3.47-2.52 (m, 2, Ar--C H 2 --CH 2 ), 2.59-2.64 (dt, 2, C H 2 --CHOH, J=2.1 Hz, J'=10.1 Hz), 2.68-2.78 (m, 4, Ar--CH 2 --C H 2 --C H 2 ), 2.87-2.99 (t, 2, C H 2 --CH 2 --CHOH, J=11.0 Hz), 3.05-3.10 (d, 2, N--C H 2 --CHN, J=10.2 Hz), 3.76-3.80 (m, 3, Ar--CH 2 --N+CH--N), 3.90 (s, 1, C H--OH), 4.55 (s, 1, OH), 6.75-7.49 (m, 8H, arom.).
Procedure G
1'-(1-(4-Iodobenzyl)-4-hydroxypiperidin-3-yl)-3,4-dihydrospiro[naphthalene-1(2H),4'-piperidine] (13e)
A mixture of the hydrochloride of 21c (250 mg, 0.67 mmol), potassium carbonate (463 mg, 3.35 mmol) and 4-iodobenzyl chloride (298 mg, 1.00 mmol) in absolute ethanol (25 mL) was refluxed for 16 h. When the mixture had cooled, salts were filtered off and the volatiles were removed under reduced pressure. The residue was dissolved in ethyl acetate (25 mL) and the solution was successively washed with water (25 mL) and brine (25 mL). The organic layer was then dried (Na 2 SO 4 ) and concentrated. The product was purified by chromatography (silica gel, hexanes/ethyl acetate: 50/50) and (13e) was obtained as a colorless oil (226 mg, 52%). The hydrochloride was prepared in a satd HCl/ether soln and recrystallized twice from 50% isopropyl alcohol-hexanes to yield a yellow powder; mp 256.3° C.; 1 H NMR (CDCl 3 ) δ1.56-2.18 (2 m, 8, 2 N--C H 2 --C H 2 ), 2.40-2.45 (d, 2H, Ar--C H 2 --CH 2 , J=10.1 Hz), 2.51-2.60 (m, 2, C H 2 --CHOH), 2.72-2.78 (m, 4, Ar--CH 2 -C H 2 --C H 2 ), 2.84-2.97 (t, 2, N--C H 2 --CH 2 --CHOH, J=11.9 Hz), 3.05-3.50 (d, 2, CHN--C H 2 --N, J=10.4 Hz), 3.40-3.55 (m, 4, C H--OH+Ar--CH 2 --N+CHN), 3.81 (s, 1, OH), 7.22-7.02 (m, 4, arom.), 7.42-7.46 (d, 2, arom., J=7.7 Hz), 7.63-7.67 (d, 2, arom., J=8.2 Hz).
1'-(2-Hydroxy-1,2,3,4-tetrahydronaphth-3-yl)-spiro[2-bromo-1H-indene-1,4'-piperidine]Hydrochloride (14)
Compound 24 was prepared from 2-bromo-1H-indene by Procedure H, below, and purified by radial flow chromatography in silica gel (hexanes,94:acetone,5:Et 3 N, 1) to yield 3.0 g (57%) of a golden yellow syrup; 1 H NMR (CDCl 3 ) δ1.24-1.29 (d,2,piperidyl β-H eq ), 1.44-1.54 (s,9,t-butoxy), 2.04-2.12 (m,2,piperidyl β-H ax .), 3.45-3.60 (m,2, piperidyl α-H ax ), 4.21-4.35 (br s, piperidyl α-H eq ), 6.85 (s,1, indenyl C3-H), 7.13-7.31 (m,indenyl C4-,C5- fr C6-H), 7.80 (d,1, indenyl C7-H). Compound 24 (2.8g, 7.85 mmol was converted to 25 in as described for 21a above. This product was added to a soln of 1,4-dihydronaphthalene oxide, prepared from the corresponding bromohydrin (9.0 mmol as described in Procedure B above, in EtOH (10 mL) and Et 3 N (10 mL. The resulting mixture was refluxed for 40 h, cooled to r.t. and cone in vacuo. The residue partitioned between CH 2 Cl 2 (50 mL) and said NaHCO 3 (30 mL). After separation of the phases, the aq. layer was re-extracted with CH 2 Cl 2 (2×30 mL). The combined organic extracts were dried over anhyd. Na 2 SO 4 and conc to a residue. The latter was subjected to radial flow chromatography on silica gel (hexanes,79:acetone,20:Et 3 N, 1) to provide 1.92 g (60%) of 14 as a syrup. 1 H NMR (CDCl 3 ) δ1.43 (d, 2, piperidyl β-H eq , J=10.5 Hz), 2.13-2.32 (m, 2, piperidyl β-H ax ), 2.81-3.49 (m, 9, tetrahydronaphthyl C1-H, C3-H, C4-H & piperidyl α-H), 3.96 (m, 1, C HOH), 6.88 (s, 1, indenyl C3-H), 7.02-7.97 (m, 7, aryl), 7.81 (d, 1, indenyl C7-H, J=7.2 Hz). The corresponding hydrochloride was obtained in cold methanolic HCl and recrystallized from i-PrOH as an off-white solid; mp 278°-281° C.
1'-(2-Hydroxy-1,2,3,4-tetrahydronaphth-3-yl)-spiro[4-bromo-1H-indene-1,4'-piperidine]Hydrochloride (15)
The reaction of 7-bromo-1H-indene (3.50 g, 17.94 mmol, with LiN[Si(CH 3 ) 3 ] 2 and bis(2-chloroethyl)-tert-butyl carbamate (Procedure H) yielded a mixture of two products (5.85g, 90%) in a ratio of 85:15, respectively, as revealed by HPLC (silica gel, 2% acetone-hexanes). Deprotection (see 21a), subsequent neutralization and extraction into EtOAc yielded, after concentration, 2.2 g (46%) of the crude free base. Trituration of this residue with CH 2 Cl 2 yielded 27 as a white solid which was collected by filtration, washed with CH 2 Cl 2 and dried at 50° C. in vacuo; mp 310°-315° C. (sinters); 1 H NMR (DMSO d6 ) δ1.30 (d, 2, piperidyl α-H eq , J=13.5 Hz), 2.38 (dt, 2, piperidyl δ-H ax , J=12.9 Hz, J'=4.8 Hz), 3.21 (dt, 2, piperidyl α-H ax , J=13.4 Hz, J'=2.4 Hz), 3.35 (d, 2, piperidyl α-H eq , J=11.1 Hz), 6.78 (d, 1, indenyl C2-H, J=6.0 Hz), 7.14 (t, 1, indenyl C6-H, J=8.4 Hz), 7.26 (d, 1, indenyl C2-H, J=6.0 Hz), 7.29 (d, 1, indenyl C5-H, J=6.0 Hz), 7.40 (d, 1, indenyl C7-H, J=8.4 Hz). A soln of 1M Et 3 Al in toluene (0.65 mL) was added dropwise at room temperature, under N 2 , to a stirring suspension of 27 (0.30 g, 1.13 mmol) in CH 2 Cl 2 (13 mL).
Complete dissolution occurred at the end of the addition. The resulting soln was stirred at r.t. for 40 min at which time a soln of 1,4-dihydronaphthalene oxide in CH 2 Cl 2 (5 mL), prepared from the corresponding bromohydrin (1.35 mmol) as described in Procedure B above, was added dropwise over 5 min. Stirring was contd for 21 h. The reaction was quenched by dropwise addition of 4N NaOH (20 mL). The resulting mixture was stirred vigorously for 2 h, diluted with H 2 O (25 mL) and extracted with CH 2 Cl 2 (3×30 mL). The combined organic extracts were dried over NaSO 4 and cone to a tan solid which was purified by radial flow chromatography on silica gel (hexanes,79:acetone,20:Et 3 N,1) to yield an off-white solid (0.30g, 65%); mp 265°-267° C.; 1 H NMR (CDCl 3 ) δ1.45 (d, 2, piperidyl β-H eq , J=12.9 Hz), 2.10-2.28 (m, 2, piperidyl α-H ax ) 2.65 (t, 1, piperidyl α-H ax , J=11.4 Hz), 2.81-3.11 (m, 7, tetrahydronaphthyl C1-H, C4-H & piperidyl), 3.35 (dd, 1, piperidyl a-H eq , J=16.1 Hz, J'=5.7 Hz), 3.93 (m, 1, C HOH), 6.87 (d, 1, indenyl C2-H, J=5.7 Hz), 6.96 (d, 1, indenyl C3-H, J=5.7 Hz), 7.12 (m, 5, aryl), 7.31 (d, 1, indenyl C5-H, J=7.4 Hz), 7.38 (d, 1, indenyl C7-H, J=7.9 Hz).
Procedure H
5-Bromo-1'-tert-butoxycarbonylspiro[1H-indene-1,4'-piperidine] (29) and 6-Bromo-1'-tert-butoxycarbonyl spiro[1H-indene-1,4'-piperidine] (30)
A soln of 1M LiN[(Si CH 3 ) 3 ] 2 in THF (45 mL) was added dropwise over 20 min, under N 2 , to a cooled (icebath) stirring soln of 5-bromo-1H-indene (3.90 g, 20.0 mmol) in dry THF (15 mL). Following the addition, stirring was contd at 4° C. for 45 min. The dark soln was then transferred via cannula to a precooled (icebath) solution of N,N-bis(2-chloroethyl)-tert-butyl carbamate (4.84 g, 20.0 mmol in dry THF (15 mL). The resulting solution was stirred at 4° C. for 2 h and then at r.t. for 18 h. The dark purple mixture was cone in vacuo, and the residue was triturated with a small volume of 20% acetone-hexanes and applied into a short silica gel column. The latter was eluted with the same solvent (300 mL). The eluent was concentrated to yield 6.45 g (88% ) of the crude mixture of 29and 30 which was considered pure enough for use without further purification. However; a small fraction of this material was purified by radial flow chromatography on silica gel (hexanes, 89:acetone, 10:Et 3 N, 1) to provide an orange colored syrup; 1 H NMR (CDCl 3 ) δ1.30 (d, 2, piperidyl β-H eq , J=16.8 Hz), 1.50 (s, 9, t-butoxy), 1.96 (dt, 2, piperidyl β-H ax , J=12.3 Hz, J'=4.6 Hz), 3.09 (t, 2, piperidyl α-H ax , J=13.0 Hz), 4.17 (b-d, 2, piperidyl α-H eq , J=13.0 Hz), 6.71 (d, 1, indenyl C2-H, J=5.78 Hz), 6.85 (m, 1, indenyl C3-H), 7.14-7.45 (m, 3, aryl). Anal. (C 18 H 22 BrNO 2 ) C,H,N.
1'-(2-Hydroxy-1, 2,3,4-tetrahydronaphth-3-yl)-spiro[5-bromo-1H-indene-1,4'-piperidine]Hydrochloride (16) and 1'-(2-Hydroxy-1,2,3,4-tetrahydronaphth-3-yl)spiro[6-bromo-1H-indene-1,4'-piperidine]Hydrochloride (17)
HCl(g) was vigorously bubbled through a cooled (icebath) solution of 29 and 30 (6.20 g, 17.0 mmol) in EtOAc (100 mL). The resulting soln was stirred at 4° C. for an additional 45 min and cone in vacuo to a brown solid. The latter was triturated with Et 2 O, filtered, washed with Et 2 O and dried to afford 4.12 (80%) of a mixture of isomeric bromospiro[1H-indene- 1,4-piperidine) hydrochlorides. A fraction of this mixture (2.0 g, 6.65 mmol) was added to a soln of 1,4-dihydronaphthalene oxide, prepared from corresponding bromohydrin (1.61 g, 7.1 mmol), in EtOH (50 mL) and Et 3 N (20 mL). The mixture was refluxed for 72 h, cooled to r.t. and cone in vacuo to a syrup. The latter was diluted with CH 2 Cl 2 and the soln was washed with satd NaHCO 3 (40 mL). The aq. layer was re-extracted with CH 2 Cl 2 (40 mL) and set aside. The combined organic extracts were dried over Na 2 SO 4 and conc to a residue. Radial flow chromatographic separation (hexanes, 89:acetone,10:Et 3 N,1) yielded a small fraction of starting material (0.30 g, 17%) and two products. The more mobile product, 16, was obtained as a white powder (0.2 g, 10%) which was converted to the hydrochloride in MeOH and recrystallized from isopropyl alcohol; mp 259°-263° C.; 1 H NMR (CDCl 3 ) δ1.44 (d, 2, piperidylβH eq , J=12.8 Hz), 2.08-2.30 (m, 2, piperidyl βH ax ,), 2.64 (t, 1, piperidyl α-H ax , J=9.8 Hz), 2.59-3.12 (m, 7, tetrahydronaphthyl C1-H, C4-H & piperidyl), 3.35 (dd, 1, piperidyl αH- eq , J=16 Hz, J'=5.8 Hz), 3.94 (m, 1, C HOH), 6.72 (d, 1, indenyl C2-H, J=5.6 Hz), 6.90 (d, 1, indenyl C3-H, J=5.7 Hz), 7.14 (s, 4, tetrahydronaphthyl C5-H, C6-H, C7-H, C8-H), 7.18 (d, 1, indenyl C7-H, J=8.1 Hz), 7.38 (dd, 1, indenyl C6-H, J=7.9 Hz, J'=1.6 Hz), 7.53 (d, 1, indenyl C4-H, J=7.6 Hz).
The less mobile product, 17, was also obtained in 10% yield, and converted to the hydrochloride in a similar manner; mp 269 -270° C. 1 H NMR (CDCl 3 ) δ1.43 (d, 2, piperidyl β-H eq , J=13.2 Hz), 2.16 (m, 2, piperidyl β-H ax ), 2.64 (t, 1, piperidyl α-H ax , J=9.8 Hz), 2.79-3.12 (m, 7, tetrahydronaphthyl C1-H, C4-H & piperidyl), 2.94-3.40 (dd, 1, piperidyl α-H eq , J=16.1 Hz, J'=5.7 Hz), 3.94 (m, 1, C HOH), 6.72 (d, 1, indenyl C2-H, J=5.7 Hz), 6.92 (d, 1, indenyl C3-H, J=5.6 Hz), 7.14 (s, 5, tetrahydronaphthyl C5-H, C6-H, C7-H, C8-H), 7.27 (d, 1, indenyl C4-H, J=6.6 Hz), 7.36 (dd, 1, indenyl C5-H, J=7.9 Hz, J'=1.7 Hz), 7.48 (d, 1, indenyl C7-H, J=1.6 Hz).
TABLE 1__________________________________________________________________________Pharmacological Activity of Spirovesamicols in Male Wistar RatsDose (umol/Kg)Compound 1 5 10 12.5 20 22.5 25 45 50 125__________________________________________________________________________ 15 - NR +14 + LD.sub.100 LD.sub.100 13d NR S LD.sub.10011a + ++ LD.sub.10011b ++ LD.sub.100 LD.sub.100 LD.sub.100__________________________________________________________________________
TABLE 2__________________________________________________________________________Pharmacological Activity of Spirovesamicols in Male Swiss Webster MiceDose (umol/Kg)Compound 1.25 2.5 5.0 6.25 10 12.5 20 25 40 50 100__________________________________________________________________________11a NR + LD.sub.40 LD.sub.60 LD.sub.10011b + LD.sub.20 LD.sub.20 LD.sub.40 LD.sub.60 LD.sub.100__________________________________________________________________________
Legend for Table 1 and 2
Rats and mice were injected intraperitoneally with solutions of the compounds in aqueous EtOH (or aqueous DMSO). The animals were observed for signs of anticholinergic activity: spasms, respiratory distress and paralysis. At lethal doses, death generally occurred within 20 minutes following the injection. LD 20 lethal dose for 20% of animals tested; LD 40 , lethal dose for 40%; LD 60 , lethal dose for 60%; L 100 , lethal dose for all animals; NR, no visible pharmacologic reaction; S, sluggishness and reduced locomotor activity; +, mild symptoms of anticholinergic activity; ++, severe signs of anticholinergic activity.
TABLE 3______________________________________Inhibitory potency of SpirovesamicolsCompound Ki (nM)______________________________________ 1 1.011a 0.622 ± 0.08211b 0.121 ± 0.03211c 0.798 ± 0.18711d 0.264 ± 0.07811f 0.248 ± 0.02513a 24.25 ± 5.7113b 18.36 ± 14.0313c 5.80 ± 1.7013d 0.082 ± 0.02013f 2.60 ± 0.9014 0.038 ± 0.00615 0.212 ± 0.06316 1.40 ± 0.3017 0.271 ± 0.056______________________________________
TABLE 4______________________________________Elemental Analyses C H NCom- Calc Calc Calcpound Formula Found Found Found______________________________________11a C.sub.19 H.sub.25 NO.HCL. 1/2H.sub.2 O 69.39 8.28 4.26 68.89 8.20 4.1311b C.sub.23 H.sub.25 NO.HCL. 1/2H.sub.2 O 73.29 6.95 3.72 73.34 7.29 3.4411c C.sub.25 H.sub.29 IN.sub.2 O--2HCl. 1/4H.sub.2 O 51.96 5.50 4.85 51.93 5.79 4.8011d C.sub.25 H.sub.29 INO--2HCl. 1/4H.sub.2 O 51.55 5.53 4.81 51.45 5.89 4.5711e C.sub.25 H.sub.29 lN.sub.2 O.2HCl. 3/4H.sub.2 O 51.17 5.58 4.77 50.89 5.69 4.8011f C.sub.25 H.sub.29 FNO.2C.sub.2 H.sub.2 O.sub.4 60.81 5.81 4.89 62.52 6.18 5.3212a C.sub.19 H.sub.27 NO.HCl. 1/4H.sub.2 O 70.04 8.73 4.27 69.86 8.72 4.2812b C.sub.23 H.sub.27 NO.HCl. 1/2H.sub.2 O 69.28 7.42 3.60 69.59 7.87 3.5312c C.sub.25 H.sub.31 IN.sub.2 O.2HCl. 1/2H.sub.2 O 51.38 5.86 4.80 51.24 5.72 4.7712d C.sub.25 H.sub.31 IN.sub.2 O.2HCl. 1/2H.sub.2 O 51.38 5.86 4.80 51.27 5.82 4.6012e C.sub.25 H.sub.31 IN.sub.2 O.2HCl. 1/2H.sub.2 O 51.38 5.86 4.80 51.04 5.76 4.7012f C.sub.25 H.sub.31 FN.sub.2 O.2C.sub.2 H.sub.2 O.sub.4 60.61 6.14 4.88 61.37 6.53 5.0113a C.sub.20 H.sub.29 NO.HCl 71.51 9.00 4.17 71.35 9.05 4.1313b C.sub.24 H.sub.29 NO.HCl 72.52 7.99 3.52 72.52 7.98 3.5313c C.sub.26 H.sub.33 IN.sub.2 O.2HCl.H.sub.2 O 51.41 6.14 4.61 51.63 6.02 4.6213d C.sub.26 H.sub.33 IN.sub.2 O 60.47 6.44 5.42 60.35 6.47 5.3613e C.sub.26 H.sub.33 IN.sub.2 O.2HCl.H.sub.2 O 51.41 6.14 4.61 51.16 6.12 4.5913f C.sub.26 H.sub.33 FN.sub.2 O.2HCl 64.86 7.33 5.82 59.40 7.61 5.3620a C.sub.23 H.sub.32 N.sub.2 O.sub.3 71.84 8.39 7.29 71.60 8.53 7.2220b C.sub.23 H.sub.34 N.sub.2 O.sub.3 71.46 8.87 7.25 70.47 8.84 7.21(dl)20c C.sub.24 H.sub.36 N.sub.2 O.sub.3 71.96 9.06 6.79 71.92 9.09 7.02(+)-20c C.sub.24 H.sub.36 N.sub.2 O.sub.3 71.96 9.06 6.79 71.93 9.10 6.87(-)-20c C.sub.24 H.sub.36 N.sub.2 O.sub.3 71.96 9.06 6.79 71.78 9.08 6.9219c C.sub.24 H.sub.36 N.sub.2 O.sub.3 71.96 9.06 6.79 71.77 9.07 6.90 29 + 30 C.sub.18 H.sub.22 BrNO.sub.2 59.35 6.09 3.85 59.04 6.16 3.86 14 C.sub.23 H.sub.24 BrClNO.HCl 61.83 5.64 3.13 61.58 5.60 3.12 15 C.sub.23 H.sub.24 BrClNO.HCl.H.sub.2 O 59.43 5.64 3.01 58.00 5.66 3.00 16 C.sub.23 H.sub.24 BrClNO.HCl 61.83 5.64 3.13 61.70 5.68 3.13 17 C.sub.23 H.sub.24 BrClNO.HCl 61.83 5.64 3.13 61.77 5.66 3.13______________________________________
Methods for the introduction of aryl and heteroaryl groups into the C2 and C3 positions of indene have been reported (Greifenstein et al., 1981). Those of ordinary skill in the art may make these variations readily.
FIG. 5 shows the potency of vesamicol analogs at human sigma receptors. Each analog was incubated in the presence of 5 nM (+)-[ 3 H]PPP in 10 mM Tris buffer for 1 hr at 25° C. Nonspecific binding was determined in the presence of 100 μM (dl)-pentazocine. The fraction of sites occupied (inhibited) by each analog at a dose of 1 μM is shown. Each point represents a mean of three determinations. The Y axis is % Sites Occupied.
USES
These compounds are useful for many applications. They may be used in a method for noninvasively mapping cholinergic innervation in a living brain, which comprises injecting a subject with an effective amount of a radioiodinated spirovesamicol or other radiolabeled compound based on a spirovesamicol with a chelating sidechain complexed with a radionuclide such as Tc-99 m, Re-18b and Ga-68 which emits gamma or positron radiation capable of tissue penetration and subsequent external detection by a photoscanning device; and subsequently scanning with said photoscanning device to visualize cholinergic innervation.
The spirovesamicols may be used in a method for photoaffinity labelling of the vesamicol protein, which comprises treatment of tissues with an effective amount of photoaffinity label including spirovesamicol wherein the sidechain is azidoaryl, azidoarylalkyl, azidoaroyl, azidoheteroaryl or azidoheteroaroyl; and inducing chemical bond formation between the azido group and the vesamicol receptor by exposure to light.
The spirovesamicols may be used in a method for visualization of cholinergic innervation in the mammalian brain which comprises the application of an effective amount of a spirovesamicol including a sidechain containing a fluorescent or visible dye or chromophore; and subsequent visualization of the tissue with light.
The spirovesamicols may be used in a method for blocking cholinergic neurotransmission in mammals or other animals which involves the application of a spirovesamicol composition as an active ingredient including a sidechain that is alkyl, arylalkyl, cycloalkyl, heteroalkyl or acyl. Examples include uses with rhinitis and operoneuron disease.
The spirovesamicols may be used in a method for noninvasive detection of cholinergic innervation in a living brain, which comprises injecting a subject with an effective amount of a magnetic resonance contrast agent comprising a spirovesamicol with a chelating sidechain complexed with a paramagnetic cation capable of enhancing contrast in magnetic resonance imaging; and subsequently scanning with a magnetic resonance imager.
The spirovesamicols may be used in a method for autoradiographic visualization of the distribution of cholinergic pathways in animal tissue which comprises introduction by injection to a subject or incubation of a tissue sample with a radiolabelled spirovesamicol with a sidechain containing a radiolabel; and subsequent visualization by autoradiography.
While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | The compounds are vesamicol (hydroxylated phencyclidine (PCP) isomer trans-2-(4-phenyl-piperidino)cyclohexanol) derivatives with anticholinergic properties termed herein "spirovesamicols" which are spirofused piperidines. The compounds bind to the vesamicol receptor, a site on the cholinergic synaptic vesicle, which is associated with the vesicular transporter of acetylcholine. | 0 |
[0001] The present invention relates to a desulphurization process employing a catalyst containing at least one support, and an active phase comprising a metal, for example. The process allows hydrodesulphurizing gasoline, more particularly gasoline from a catalytic cracking process (fluid catalytic cracking, FCC).
[0002] The production of reformulated gasoline satisfying new environmental regulations primarily necessitates substantially reducing their sulphur content. Current and future environmental regulations within the European community require refiners to reduce the sulphur content in the gasoline pool to values of 50 ppm or less by 2005 and 10 ppm by 1 Jan. 2009. The feed to be treated is generally a gasoline cut containing sulphur, such as a cut from coking, visbreaking, steam cracking or catalytic cracking (FCC). That feed is preferably constituted by a gasoline cut derived from a catalytic cracking unit with a typical boiling point range which extends from that of hydrocarbons containing 5 carbon atoms to about 250° C. Said gasoline may optionally be composed of a significant fraction of gasoline from other production processes, such as atmospheric distillation (generally termed straight run gasoline by the refiner) or conversion processes (coker gasoline or steam cracked gasoline).
[0003] Catalytically cracked gasoline, which may constitute 30% to 50% by volume of the gasoline pool, has high olefin and sulphur contents. Almost 90% of the sulphur present in reformulated gasoline is due to gasoline derived from catalytic cracking. Desulphurizing gasoline, and principally of FCC gasoline, is thus clearly important in order to satisfy requirements. Hydrotreatment or hydrodesulphurizing catalytically cracked gasoline, carried out under conventional conditions known to skilled person, can reduce the sulphur content in the cut. However, that process suffers from the major disadvantage of causing a very large drop in the octane number of the cut due to hydrogenation or saturation of a major portion or even all of the olefins under the hydrotreatment conditions. Thus, processes that can deep desulphurize FCC gasoline while keeping the octane number to an acceptable level have been proposed. U.S. Pat. No. 5,318,690 proposes a process consisting of fractionating the gasoline, sweetening the light fraction and hydrotreating the heavy fraction over a conventional catalyst then processing it over a ZSM-5 zeolite to recover the initial octane number. International patent WO-A-01/40409 claims the treatment of FCC gasoline at high temperature, low pressure and with a high hydrogen/feed ratio. Under those particular conditions, recombination reactions, employing the H 2 S formed by the desulphurization reaction and olefins, resulting in the formation of mercaptans, are minimized.
[0004] The desired improvement in the reaction selectivity (hydrodesulphurization/hydrogenation) may thus be obtained by the choice of process, but in all cases, the use of an intrinsically selective catalytic system is imperative. In general, the catalysts used for this type of application are sulphide type catalysts containing a group VIB element (Cr, Mo, W) and a group VIII element (Fe, Ru, Os, Co, Rh, Ir, Pd, Ni, Pt).
[0005] Obtaining selective catalysts for selective hydrodesulphurizing olefinic gasoline cuts has been disclosed in many patents. Certain patents propose the use of supports other than the alumina support conventionally used for hydrotreatment catalysts, such as supports based on magnesia (U.S. Pat. No. 4,203,829; U.S. Pat. No. 4,140,626), spinel (U.S. Pat. No. 5,525,211), carbon (U.S. Pat. No. 5,770,046), hydrotalcite (U.S. Pat. No. 5,340,466). Other patents claim the use of a catalyst with a controlled mesoporosity such as U.S. Pat. No. 6,013,598 which claims the use of a catalyst with a median pore diameter (measured by mercury porismetry) in the range 7.5 to 17.5 nm. Despite these advances, the development of novel catalysts with improved selectivities remains an important objective in the field of hydrotreating cracked gasoline.
[0006] To be competitive, hydrodesulphurization processes must satisfy two principal constraints, namely:
limited olefin hydrogenation at high degrees of desulphurization; good catalytic system stability and continuous operation over several years.
[0009] Further, to carry out deep desulphurization, it is necessary to treat all of the sulphur-containing compounds present in the cracked gasoline and in this context, catalytically cracked gasoline can be classified into two families:
unsaturated sulphur-containing compounds, namely thiophene, methylthiophenes, dimethylthiophenes, ethylthiophenes, other alkylthiophenes, benzothiophenes and alkylbenzothiophenes; saturated sulphur-containing compounds, namely mercaptans, cyclic or aliphatic sulphides, disulphides.
[0012] The residual sulphur-containing compounds present in gasoline desulphurized by deep hydrodesulphurization comprise recombination mercaptans derived from the addition of H 2 S formed during the reaction to the olefins present and to unsaturated sulphur-containing compounds such as thiophene and alkylthiophenes. The presence of recombination mercaptans at least in part explains why, when seeking to deep desulphurize gasoline comprising an olefin fraction, a major increase in the degree of olefin hydrogenation is observed for high degrees of desulphurization. Thus, when the desired degree of desulphurization approaches 100%, the degree of olefin saturation is greatly increased. The use of more selective catalysts may, however, when degrees of desulphurizing close to 100% are desired, limit olefin hydrogenation or allow the formation of recombination mercaptans. One of the primary aims of deep desulphurization is thus to develop processes that can attain high selectivities, i.e. minimize olefin hydrogenation reactions while treating residual sulphur-containing compounds such as mercaptans.
[0013] Of the solutions which may be envisaged to reach the degrees of desulphurization imposed by current or future regulations, it may be advantageous to use desulphurization in at least two steps.
[0014] European patent EP-A1-1 031 622 discloses a process for desulphurizing olefinic gasoline comprising at least two steps, a step for hydrogenation of unsaturated sulphur-containing compounds and a step for decomposition of saturated sulphur-containing compounds. As described in that patent, the invention is based on a combination of two steps in which the first step eliminates unsaturated sulphur-containing compounds to saturated sulphur-containing compounds and the second step decomposes saturated sulphur-containing compounds to H 2 S with limited olefin hydrogenation.
[0015] U.S. Pat. No. 6,231,753 describes a process for hydrodesulpliurizing olefinic gasoline comprising a first hydrodesulphurization step, a step for extracting H 2 S and a second hydrodesulphurization step, the overall degree of desulphurization and the temperature of said second step being greater than those of the first.
[0016] U.S. Pat. No. 6,231,754 describes a process in which a used hydrotreatment catalyst is then used in a hydrodesulphurization step at a higher temperature. The pore diameters of the catalyst are described as being in the range 6 to 20 nm and the surface concentration of MoO 3 is in the range 0.5×10 −4 to 3×10 −4 g/m 2 .
[0017] International patent application WO-A-03/099963 describes a process in two steps in which the second step is carried out with a catalyst which is less loaded with metals and has a pore diameter that is greater than or equal to the catalyst used during the first step. The mean pore diameter is in the range 6 to 20 nm and the surface concentration of MoO 3 is in the range 0.5×10 −4 to 3×10 −4 g/m 2 .
SUMMARY OF THE INVENTION
[0018] The present invention describes a process that can reduce the total sulphur content of hydrocarbon cuts and preferably FCC gasoline cuts without losing the gasoline yield and minimizing the reduction in octane number.
[0019] The process for hydrodesulphurizing a gasoline of the invention employs a catalyst comprising a support and an active phase comprising at least one metal, characterized in that the mean pore diameter of said catalyst is more than 20 nanometers, preferably in the range 20 to 100 nm.
[0020] Preferably, the catalyst of the invention contains at least one group VI metal; more preferably it also contains at least one group VIII metal. The surface density of the group VI metal is preferably in the range 2×10 −4 to 40×10 −4 grams of the oxide of said metal per m 2 of support.
[0021] In the process of the invention, the support is preferably selected from the group constituted by aluminas, silica, silica aluminas and oxides of titanium or magnesium, used alone or mixed with alumina or silica alumina. More preferably, the support is at least partially constituted by an alumina. In a variation of the invention, the specific surface area of the support is less than 200 m 2 /g.
[0022] In a preferred variation, the hydrodesulphurization process of the invention comprises at least two successive hydrodesulphurization steps and a catalyst with a mean pore diameter of more than 20 nanometres is employed in at least one of said steps. Preferably, the successive steps are carried out without intermediate degassing.
[0023] In accordance with one implementation of the process of the invention, it comprises a succession of hydrodesulphurization steps and the activity of a catalyst in a step n+1 is in the range 1% to 90% of the activity of the catalyst in step n.
[0024] In accordance with a further implementation of the process of the invention, the reaction temperature in step n+1 is higher than that in step n. In accordance with a further implementation, the catalyst of step n+1 is the catalyst of step n which has undergone partial deactivation. In this case, for example, the catalyst may be deactivated by bringing the catalyst into contact with a feed containing a hydrocarbon fraction comprising olefins at a temperature of at least 250° C. It is also possible to recycle the catalyst of step n to step n+1 when its activity has reduced by at least 10%. A further possibility is that the catalyst of step n+1 has a metals content which is lower than that of the catalyst of step n.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The process of the invention employs at least one hydrodesulphurization catalyst comprising at least one group VI metal (M VI ) and/or at least one group VIII metal (M VIII ) on a support. The group VI metal is generally molybdenum or tungsten; the group VIII metal is generally nickel or cobalt. The catalyst support is normally a porous solid selected from the group constituted by aluminas, silicon carbide, silica, silica-aluminas or titanium or magnesium oxides used alone or mixed with alumina or silica-alumina. It is preferably selected from the group constituted by silica, the transition alumina family and silica-aluminas. Highly preferably, the support is essentially constituted by at least one transition alumina, i.e. it comprises at least 51% by weight, preferably at least 60% by weight, more preferably at least 80% by weight or even at least 90% by weight of transition alumina. It may optionally be constituted solely by a transition alumina.
[0026] The specific surface area of the support is generally less than 200 m 2 /g, usually less than 150 m 2 /g. The porosity of the catalyst prior to sulphurization is such that it has a mean pore diameter of more than 20 nm, preferably more than 25 nm or even more than 30 nm and usually in the range 20 to 140 nm, preferably in the range 20 to 100 nm, and highly preferably in the range 25 to 80 nm. The pore diameter is measured by mercury porosimetry using ASTM D4284-92 with a wetting angle of 140°.
[0027] The surface density of the group VI metal in accordance with the invention is in the range 2×10 −4 to 40×10 −4 grams of the metal oxide per m 2 of support, preferably in the range 4×10 −4 to 16×10 −4 gm 2 .
[0028] According to the invention, the molar ratio M VIII /(M VI +M VIII ) is typically more than 0.1, preferably in the range 0.2 to 0.6 and highly preferably in the range 0.2 to 0.5.
[0029] The catalyst of the invention may be prepared using any technique which is known to the skilled person, in particular by impregnating group VIII and VIB elements onto the selected support. Impregnation may, for example, be carried out using the procedure known to the skilled person as dry impregnation, in which the exact quantity of the desired elements required to fill the pores of the support as precisely as possible is introduced in the form of soluble salts in the selected solvent, for example demineralized water. The support thus filled with solution is then preferably dried. The preferred support is alumina, which may be prepared from any type of precursor and forming tool that is known to the skilled person.
[0030] After introducing the group VIII and VIB elements, and optional forming of the catalyst, it undergoes an activation treatment. Said treatment is generally aimed at transforming the molecular precursors of the elements into the oxide phase. In this case, it is an oxidizing treatment, but direct reduction or even simply drying the catalyst may also be carried out. In the case of an oxidizing treatment, also known as calcining, this is generally carried out in air or diluted oxygen, and the treatment temperature is generally in the range 200° C. to 550° C., preferably in the range 300° C. to 500° C. In the case of a reducing treatment, this is generally carried out in pure hydrogen or, as is preferable, is diluted, and the treatment temperature is generally in the range 200° C. to 600° C., preferably in the range 300° C. to 500° C.
[0031] Examples of salts of group VIB and VIII metals which can be used in the process for preparing the catalyst are cobalt nitrate, nickel nitrate, ammonium heptamolybdate and ammonium metatungstate. Any other salt which is known to the skilled person, has sufficient solubility and can decompose during the activation treatment may be used.
[0032] The catalyst is normally used in the sulphide form obtained after treatment at temperature in contact with an organic sulphur-containing compound which is decomposable and which can generate H 2 S or directly in contact with a gaseous stream of H 2 S diluted in H 2 . This step may be carried out in situ or ex situ (inside or outside) the hydrodesulphurization reactor at temperatures in the range 200° C. to 600° C. and more preferably in the range 300° C. to 500° C.
[0033] The present invention also pertains to a process for desulphurizing gasoline comprising olefins, comprising at least two hydrodesulphurization steps and intended to minimize both the amount of the compounds most refractory to hydrodesulphurization, such as thiophenes and recombination mercaptans, derived from adding H 2 S to olefins while limiting the degree of olefin hydrogenation, associated with elimination of sulphur-containing compounds. At least one of the steps in the hydrodesulphurization process employs a catalyst as described above.
[0034] At least partial extraction of H 2 S between the two reactors using any means known to the skilled person is a known solution for achieving high degrees of desulphurization with a limited degree of olefin hydrogenation. In one possible implementation, that type of scheme may be applied in the context of the present invention. However, since an H 2 S extraction step involves an extra cost in the process, the present process is of particular advantage in the case in which the hydrodesulphurization reactors are concatenated without H 2 S elimination between the reactors.
[0035] The process comprises at least two steps. A first step A for hydrodesulphurization is preferably carried out in a fixed bed reactor, generally in the vapour phase, on any catalyst which is conventionally used for said application. The use of “selective” catalysts is preferred as they can limit olefin hydrogenation while maximizing hydrodesulphurization. This first step is followed by a second step B, for example with no operations between steps A and B apart from reheating the effluent from step A. Step B is characterized in that it is carried out using a catalyst having a catalytic activity for thiophene conversion in the range 1% to 90%, or even in the range 1% to 70% and preferably in the range 1% to 50% of the activity of the catalyst of step A. The catalyst employed in step B may be either a catalyst the catalytic formulation of which has been optimized to reach the desired catalytic activity, or a partially deactivated catalyst.
[0036] In accordance with the invention, the use of catalysts which are preferably more selective in series can limit olefin hydrogenation at high degrees of desulphurization. It has been observed that such a combination may, by means of a cheaper device, significantly improve the selectivity of the desulphurization reaction by minimizing the degree of olefin saturation while maintaining a high degree of transformation of sulphur-containing compounds to H 2 S. That device also has the advantage that, for a scheme with no H 2 S extraction between the two reactors, it can improve the selectivity of the process with respect to desulphurization carried out in a single step. Compared with the disclosure in EP-A1-1 031 622, carrying out the present process can achieve higher degrees of desulphurization for the same degree of olefin hydrogenation as the unsaturated compounds which are not converted in the first step may be converted in the second step.
[0037] In the particular case in which the catalyst of step B is the same catalyst as that of step A, but with a catalytic activity which has been reduced by deactivation, the device is usually based on an assembly of at least two or even three reactors and may be carried out as follows: the reactor for step A contains fresh catalyst and the reactor for step B contains the used catalyst. When the catalyst of step A is deactivated, the reactor containing the deactivated step A catalyst is used in the second step, a reactor containing fresh catalyst being fired up and placed at step A. The reactor containing catalyst B is stopped, the catalyst is replaced with fresh catalyst and the reactor is placed on standby. This scheme means that the desulphurization unit can be operated continuously when replacing used catalyst while maximizing process selectivity.
[0038] This implementation is particularly advantageous when operating the hydrodesulphurization section at low pressures and high temperatures for the two steps, conditions under which the formation of recombination mercaptans is minimized but which causes rapid deactivation of the hydi-odesulphurization catalysts. The term “low pressure” means relative pressures that are generally less than 2 MPa relative and preferably less than 1.5 MPa relative or even less than 1 MPa relative, and temperatures that are generally more than 250° C. or even 260° C. and usually more than 280° C.
[0039] Step A is generally characterized by:
a degree of desulphurization which is generally less than 98%, preferably less than 95% and more preferably less than 90%; a degree of olefin hydrogenation which is less than 60% and preferably less than 50%.
[0042] Step B is usually characterized by:
a degree of desulphurization which is generally less than 98%, preferably less than 95% and more preferably less than 90%; a degree of olefin hydrogenation which is less than 60% and preferably less than 50%; an operating temperature which is higher than that of step A, preferably higher by more than 10° C. than the temperature in step A and more preferably higher by more than 20° C. than the temperature in step A; the use of a catalyst the activity per unit volume of which, measured by thiophene conversion, is in the range 1% to 90% of the activity of the catalyst of step A. Said catalytic activity is measured using a model molecule test described below.
[0047] The pressure in steps A and B is generally in the range 0.4 MPa relative to 3 MPa relative, preferably in the range 0.6 MPa to 2.5 MPa; the hydrogen flow rate is such that the ratio of the flow rates of hydrogen in normal litres per hour to the flow rate of hydrocarbons in litres per hour is in the range 50 to 800, preferably in the range 60 to 600. The temperature in step A is in the range 150° C. to 450° C., preferably in the range 200° C. to 400° C. and more preferably in the range 230° C. to 350° C. and the temperature in step B is in the range 150° C. to 450° C., preferably in the range 210° C. to 410° C. and more preferably in the range 240° C. to 360° C.
[0048] Steps A and B are carried out in a preferred mode in a combination without a supplemental intermediate step. Thus, it is possible to employ them in the same reactor. In this case, the catalytic zone corresponding to step B is operated at a mean temperature that is higher by a minimum of 10° C. than in the catalytic zone corresponding to step A. This difference in temperature may derive either from the heat of reaction released by olefin hydrogenation or by injecting a hotter fluid selected from hydrogen or an inert gas such as nitrogen, the feed or the fluid derived from recycling a fraction of the effluent of the process between the catalytic zones A and B.
[0049] Steps A and B may also be employed in a catalytic colum from which overhead compounds which are gaseous under normal temperature and pressure conditions are extracted. In this case, the catalytic zone of step A is disposed higher in the column than the catalytic zone of step B.
[0050] The catalyst of step B advantageously differs from the catalyst of step A by a catalytic activity in the range 1% to 90%, or even in the range 1% to 70% and preferably in the range 1% to 50% of the catalytic activity of the catalyst of step A the catalysts for steps A and B are used in the sulphurized form. The sulphurization procedure may be carried out in situ or ex situ using any sulphurization method known to the skilled person.
[0051] The activity of the catalyst is defined by the ratio of the rate constant for conversion of normalized thiophene per volume of catalyst determined during a model molecule test. The rate constant is calculated by assuming that the following reaction is 1 st order:
A=k /( m catalyst ×CPD catalyst )
in which:
[0052] A: activity of catalyst in min −1 .cm 3 catalyst −1 (cubic centimeter −1 )
k: rate constant for thiophene conversion, in min −1 ; m catalyst : mass of catalyst used in g; CPD: packed catalyst density, in cm 3 /g.
[0056] When the catalyst used is a new catalyst prepared to have a reduced activity, new catalyst may be prepared by impregnating a small quantity of metals onto the support. Typically, the amounts of group VIII and group VIB metals deposited on the support will not exceed 10.9% and 14% by weight respectively in the oxide form and preferably 7.8% and 10% by weight respectively in the oxide form (to remain coherent with the maximum Co/Co+Mo ratio of 0.6 for the preferred range). The support used generally contains silicon, silicon carbide, titanium oxide or magnesium oxide and/or alumina, but is preferably mainly composed of alumina.
[0057] The catalyst of step B may also be a deactivated hydrotreatment catalyst. As an example, a used catalyst from a distillate hydrodesulphurization unit or from any other hydrodesulphurization process present in the refinery may be employed, provided that the residual activity measured by the method described in Example 6 does not exceed 90% or 70% and preferably 50% of the activity of the catalyst from step A.
[0058] Finally, the catalyst of step B can have an identical formulation to that of step A, but after having undergone deactivation by treatment of a cut comprising olefins. The used catalysts generally have an activity reduced by the presence of a deposit of carbon due to polymerization of the hydrocarbons treated over the catalyst.
[0059] The present invention may be implemented as follows: the gasoline to be treated is, for example, characterized by a sulphur content of more than 50 ppm and an olefins content of more than 10%; at least 70% of the sulphur is intended to be converted into H 2 S. This gasoline, which has boiling points which are generally less than 250° C., may either be treated directly using the device of the present invention, or it can undergo pretreatment consisting of a selective hydrogenation step and fractionation. Said pretreatments are described in detail in European application EP-A-0 1 077 247. In this case, advantageously only the C 6 +(i.e. containing hydrocarbons with a total number of carbon atoms of 6 or more) of the gasoline may be treated by the process of the present invention.
[0060] The gasoline, mixed with hydrogen, is heated in an exchanger train and/or an oven. The mixture, heated to the desired temperature and pressure, is generally in the vapour phase. It is sent to a first reactor (step A) containing a hydrodesulphurization catalyst as described above, used in fixed bed mode. The effluent from this reactor contains hydrocarbons and unreacted sulphur-containing compounds, paraffins derived from olefin hydrogenation, H 2 S from the decomposition of sulphur-containing compounds and recombination mercaptans derived from addition reactions of H 2 S with olefins. This effluent is generally reheated in an exchange train and/or an oven to increase its temperature by at least 10° C. and is injected into a second reactor (step B) containing a hydrodesulphurization catalyst which is less active than that described above, used in a fixed bed mode. The effluent from this reactor is constituted by hydrocarbons and a reduced quantity of sulphur-containing compounds which did not react in step A, paraffins derived from olefin hydrogenation, H 2 S derived from the decomposition of sulphur-containing compounds and a reduced quantity of recombination mercaptans derived from H 2 S-olefin addition reactions.
[0061] For a given degree of desulphurization, the combination of steps A and B can, with respect to step A alone, minimize the olefin loss by hydrogenation. The examples below illustrate the advantages of the process in one or two steps as described above. In these examples (and the preceding description), the amounts of sulphur or sulphur-containing compounds are given in ppm by weight.
EXAMPLE 1
Preparation of Catalysts
[0062] The catalysts were prepared using the same method. The synthesis protocol consisted of dry impregnating a solution of ammonium heptamolybdate and cobalt nitrate, the volume of the aqueous solution containing the metallic precursors being equal to the water take-up volume (WTV) corresponding to the mass of support to be impregnated.
[0063] The concentrations of precursors in the solution were adjusted to deposit the desired amounts by weight of metallic oxides onto the support. The solid was left to mature at ambient temperature for 12 hours, then dried at −120° C. for 12 hours. Finally, the solid was calcined at 500° C. for two hours in a stream of air (1 l/h/g). The alumina supports used were industrial supports provided by Axens with the characteristics shown in Table 1 below.
TABLE 1 characteristics of industrial alumina supports Support Shape S BET (m 2 /g)* V p (Hg)** cc/g α Beads 1.4-2.8 mm 140 1.10 β Beads 1.4-2.8 mm 80 1.09 γ Beads 1.4-2.8 mm 32 1.06 δ Beads 1.4-2.8 mm 210 0.64 *specific surface area measured by nitrogen adsorption (ASTM D3663); **total Hg intrusion pore volume.
[0064] Various CoMo type catalysts were prepared on said supports. Table 2 shows that these catalysts are essentially distinguished from each other in their textural properties for catalysts A, B, C and D and by their active phase content for catalysts E and F.
TABLE 2 characteristics s of CoMo catalysts CoO MoO 3 V (Hg)* Median pore Catalyst Support Wt % Wt % cc/g diameter**/nm A (inv) α 3.5 10.0 0.99 22 B (inv) β 3.5 9.2 0.87 54 C (inv) γ 3.6 9.8 0.85 142 D (comparative) δ 3.8 10.7 0.60 12 E (comparative) δ 1.1 3.2 0.62 11 F (inv) β 1.0 3.1 0.90 53 *total Hg intrusion pore volume; **pore diameter corresponding to intrusion volume of V P (Hg)/2.
[0065] The catalyst sulphurization protocol was identical for each catalytic test. The catalyst, in its calcined (oxide) form, was loaded into the catalytic test unit then sulphurized using a synthetic feed (4% S in the form of DMDS in n-heptane). The sulphurization conditions were as follows: HSV=2 h −1 (volume of feed/volume of catalyst/h), P 2 MPa relative, H 2 /feed 300 (NIII), T constant =350° C. (4 h, increase in T at 20° C./hour).
[0066] The sulphur content (in ppm) was evaluated in the feed and in the tests (after eliminating dissolved H 2 S) using the ISO14596 method, which enabled the degree of desulphurizing the gasoline to be calculated using the formula:
HDS (%) (sulphur in feed in ppm−sulphur in test in ppm)/(sulphur in feed in ppm)*100.
[0067] The content by weight of olefins was evaluated in the feed and in the test by gas phase chromatography; this allowed the degree of olefin hydrogenation in the gasoline to be calculated using the formula:
HDO (%)=(% by weight olefins, feed−% by weight olefins, test)/(% by weight of olefins, feed)*100
[0068] The total mercaptans content was measured in the tests by potentiometry using the ASTM D3227 method after separating the H 2 S.
EXAMPLE 2
Evaluation of Performances of Catalysts A and D
[0069] In this example, the performances of catalysts A (according to the invention) and D (comparative) were compared in selective HDS of a sulphur-containing FCC gasoline with the characteristics shown in Table 3 below.
TABLE 3 characteristics of FCC n° 1 gasoline Total sulphur (ppm) 970 Olefins (weight %) 35.7 Aromatics (weight %) 27.6 ASTM distillation: IP 37° C. EP 215° C.
[0070] The test conditions were as follows: P 2.7 MPa relative, HSV=4 h −1 , H 2 /feed=360 normal litres per litre (nl/l), T=250-280° C. Each operating condition was maintained over the time required to stabilize the catalyst both as regards hydrogenating activity and desulphurizing activity (typically 24 to 48 hours). The results obtained for catalysts A and D are shown in Table 4 below.
TABLE 4 performances of catalysts A and D for desulphurizing FCC n° 1 gasoline Catalyst A Catalyst D T (° C.) 250 260 270 250 260 S total 160 130 90 130 65 HDS/% 83.5 86.6 90.7 86.6 93.3 Olefins, % by 26.7 26.1 25.5 23.0 21.1 weight HDO/% 25.2 26.9 28.6 35.6 40.9
[0071] It will be observed that for comparable degrees of desulphurization (HDS), catalyst A has a degree of olefin hydrogenation (HDO) which is lower than for catalyst D. Catalyst A (according to the invention) was thus more selective than catalyst D (comparative).
EXAMPLE 3
Evaluation of Performances of Catalysts A and B
[0072] In this example, catalysts A (according to the invention) and B (comparative) were evaluated using FCC n° 2 gasoline which contained less sulphur than FCC n° 1 gasoline, and which had the characteristics shown in Table 5 below.
TABLE 5 characteristics of FCC n° 2 gasoline Total sulphur (ppm) 450 Olefins (weight %) 33.5 Aromatics (weight %) 28.2 ASTM distillation: IP −5° C. EP 252° C.
[0073] The test conditions were as follows: P=1.5 MPa relative, HSV=5 h −1 , H 2 /feed=360 Nl/l, T=270-280° C. Each operating condition was maintained over the time required to stabilize the catalyst both as regards hydrogenating activity and desulphurizing activity (typically 24 to 48 hours). The results obtained for catalysts A and B are shown in Table 6 below.
TABLE 6 performances of catalysts A and B for desulphurizing FCC n° 2 gasoline Catalyst A Catalyst B T (° C.) 270 280 270 280 S total 96 46 92 54 HDS/% 78.7 89.8 79.5 88.0 Olefins, % by 29.7 26.3 30.1 27.5 weight HDO/% 11.3 21.5 10.1 17.9
[0074] For similar degrees of desulphurization (HDS), catalyst B had a lower hydrogenating activity (HDO) than catalyst A. Catalyst B (according to the invention) was thus more selective than catalyst D (comparative).
EXAMPLE 4
Evaluation of Performances of Catalysts A and C
[0075] In this example, catalysts A and C were evaluated using FCC n° 3 gasoline which had been depentanized and contained a large amount of sulphur, and which had the characteristics shown in Table 7 below.
TABLE 7 characteristics of FCC n° 3 gasoline Total sulphur (ppm) 2450 Olefins (weight %) 32.1 Aromatics (weight %) 36.2 ASTM distillation: IP 39° C. EP 240° C.
[0076] The test conditions were as follows: P 1.5 MPa relative, HSV=4 h − , H 2 /feed=300 Nl/l, T=290-310° C. Each operating condition was maintained over the time required to stabilize the catalyst both as regards hydrogenating activity and desulphurizing activity (typically 24 to 96 hours). The results obtained for catalysts A and C are shown in Table 8 below.
TABLE 8 performances of catalysts A and C for desulphurizing FCC n° 3 gasoline Catalyst A Catalyst C T (° C.) 290 310 290 310 S total 420 115 645 305 HDS/% 82.9 95.3 73.7 87.6 Olefins, % by 25.0 19.7 27.1 23.2 weight HDO/% 22.1 38.6 15.6 27.7
[0077] The change in the degree of olefin hydrogenation as a function of the degree of desulphurization shows that the two catalysts had comparable selectivities. Thus, catalyst C is not more selective than catalyst A. In contrast, catalyst C was less active than catalyst A in hydrodesulphurization, which may potentially constitute a handicap as regards the service life of this type of catalyst in an industrial unit. Regarding selectivity, catalyst C remained superior to catalyst D, however (see Example 2, Table 4).
EXAMPLE 5
Preparation of a Partially Deactivated Catalyst G
[0078] A sample of 100 ml of catalyst B underwent accelerated deactivation on a pilot unit under the following conditions: the catalyst was operated at 300° C. with a mixture constituted of gasoline 4 described in Example 6 and hydrogen injected in an amount of 100 normal litres of hydrogen per litre of gasoline, with a gasoline flow rate of 400 ml/h and at a total pressure of 1 MPa relative. After 800 hours, the reactor was put into stripping mode at 120° C. in nitrogen to eliminate adsorbed hydrocarbons. The deactivated catalyst was termed catalyst G.
EXAMPLE 6
Evaluation of Catalytic Activity of Various Catalysts
[0079] The activity of catalysts B, D, E, F and G was evaluated using a hydrodesulphurization test on a mixture of model molecules carried out in a stirred 500 ml autoclave reactor. Typically, between 2 g and 6 g of catalyst were sulphurized at atmospheric pressure in a sulphurization bank with a H 2 S/H 2 mixture constituted by 15% by volume of H 2 S at 1 l/l/g of catalyst and 400° C. for two hours.
[0080] The model feed used for the activity test had the following composition: 1000 ppm of sulphur in the form of thiophene, 10% by weight of olefins in the form of 2,3-dimethyl-2-butene in n-heptane.
[0081] This reaction mixture was selected as it was Judged to be representative of a catalytically cracked gasoline. The total pressure of the system was then adjusted and maintained at 3.5 MPa relative by adding hydrogen and the temperature was adjusted to 250° C. At time t=0, the catalyst was brought into contact with the reaction mixture. Periodical removal of samples allowed the change in composition of the solution to be monitored over time by gas chromatographic analysis. The test period was selected so as to obtain final thiophene conversion values in the range 50% to 90%.
[0082] The activity of a catalyst can be defined by the ratio of the rate constant for conversion of normalized thiophene per volume of catalyst. The rate constant is calculated by assuming that the following reaction is 1 st order:
A=k /( m catalyst ×CPD catalyst )
In which: A: activity of catalyst in min −1 .cm 3 catalyst −1 (cubic centimeter −1 ) k: rate constant for thiophene conversion, in min −1 ; m catalyst : mass of catalyst used in g (before sulphurizing); CPD: packed catalyst density, in cm 3 /g.
[0088] The relative activities of catalysts B, D, E and F obtained are shown in Table 9 below.
TABLE 9 relative activities of catalysts B, D, E, F and G Catalyst B Catalyst D Catalyst E Catalyst F Catalyst G Relative 100* 120 42 31 45 activity *base.
EXAMPLE 7
Evaluation of Performances of Catalysts B, D, E, F and G in Combinations
[0089] Gasoline n° 4 described in Table 10 was used to study the performance of a combination of catalysts. This gasoline derived from a FCC unit and had been depentanized.
TABLE 10 characteristics of FCC n° 4 gasoline Total sulphur (ppm) 380 Olefins (weight %) 27.8 Olefins (weight %) 32.1 Aromatics (weight %) 33.9 ASTM distillation: IP 55° C. EP 219° C.
[0090] The combination tests were carried out in a pilot unit provided with two reactors in series, each loaded with 100 ml of catalyst.
[0091] The performances of the various combinations of catalysts were evaluated to illustrate the present invention. For each catalyst, a conventional sulphurization procedure was carried out in advance, which procedure was identical for all of the catalysts.
[0092] The base operating conditions used for the set of tests were as follows: a pressure of 1.8 MPa relative and a hydrogen to feed ratio of 400 normal litres per litre.
[0093] The temperatures were adjusted to achieve a target sulphur content in the range 10 ppm to 15 ppm. Table 11 below summarizes the performances of the various combinations under evaluation.
TABLE 11 Performances of catalysts alone or in combinations for desulphurizing FCC n° 4 gasoline Test no 1 2 3 4 5 6 7 Catalysts B D D + E B + E B + F B + G B + D Temp R1 28 27 275 280 280 280 280 Temp R2 — — 300 300 300 300 275 HSV R1 4 4 8 8 8 8 8 (h −1 ) HSV R2 — 8 8 8 8 8 (h −1 ) Overall 4 4 4 4 4 4 4 HSV (h −1 ) S effluent, 12 13 14 13 15 12 13 pm Mercaptans, 9 10 7 8 8 7 10 ppm HDO, % 28 32 24.5 21 20.1 21.4 30.6
[0094] The two reactors, placed in series, were respectively termed reactor 1 and reactor 2. The volume of catalyst in each reactor was 100 ml.
[0095] Tests 1 and 2 were carried out on catalysts B and D alone. Catalyst D was not in accordance with the invention. The olefin loss during test 1 was lower than the olefin loss in test 2 due to the difference in selectivity between catalysts B and D.
[0096] The use of catalysts E, F or G in a combination with catalysts B or D (tests, 4, 5 and 6 in accordance with the invention) improved the overall selectivity. In fact, for close sulphur contents in the tests of between 12 and 15 ppm, the olefin loss measured by the HDO was reduced compared with tests 1 and 2 carried out on a single catalyst. Further, it was observed that the best results were obtained for combinations 5 and 6 in which the catalysts used in the two steps were in accordance with the invention:
[0097] Test 7 was carried out using a combination which was not in accordance with the invention, in which reactor 2 was loaded with a more active catalyst than that loaded into reactor 1. Comparing tests 3 to 6, it can be seen that an olefin loss and a higher residual mercaptans content occurred for an equivalent sulphur content in the effluents.
[0098] Comparing the tests above shows a reduction in the quantity of mercaptans in the product obtained by carrying out the process of the invention. | A novel process is described which allows selective hydrodesulphurizing gasoline cuts containing sulphur-containing compounds and olefins. The process employs a catalyst comprising a support selected, for example, from refractory oxides such as aluminas, silicas, silica-aluminas or magnesia, used alone or as a mixture, a group VI metal, preferably Mo or W which may or may not be promoted by a group VIII metal, Co or Ni. The catalyst is characterized by a mean pore diameter of more than 22 nm. The process may comprise one or more steps. | 2 |
BACKGROUND OF THE INVENTION
There are already known electromagnetically controlled valves for the control of the passage of a fluid, comprising a body with at least one inlet passage and outlet passage for the fluid, a fixed ferromagnetic core and a movable ferromagnetic core disposed face to face in a cylindrical bore surrounded by a winding permitting creating a magnetic field to effect displacement of the movable core in the direction of the fixed core against the action of a return force.
SUMMARY OF THE INVENTION
The invention has for its object to increase the speed of reaction of valves of this type, while preventing the pressure of the fluid from exerting on the movable core a resultant force directed in the direction of its displacement.
To this end, the valve according to the invention is characterized in that at least one passage for the fluid to be controlled opens radially in the bore, at the height of the end of the movable core which is farther from the fixed core, a fixed cylindrical member being disposed in said bore and extending from the end of the bore which is opposite that containing the fixed magnetic core to a point facing the passage opening radially in the bore, an annular space being provided between this cylindrical member and the wall of the bore, the movable core having a skirt adapted to engage in this annular space.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawing shows schematically and by way of example an embodiment and a variant of the valve according to the invention.
FIG. 1 is an axial cross section of the embodiment.
FIG. 2 is a cross section on line II--II of FIG. 1.
FIG. 3 is an explicatory diagram.
FIG. 4 is a partial cross section of the variant.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is shown in FIG. 1, the valve comprises a body 1, with two passages 2 and 3 for the entry and exit of the fluid to be controlled and conversely, as the valve is provided to control the passage of the fluid in one direction or the other. The body 1 carries a casing 4 of ferromagnetic material which contains an electric winding 5 carried by a body 6 whose internal recess constitutes a cylindrical bore containing a fixed ferromagnetic core 7 and a movable ferromagnetic core 8.
A cylindrical member 9 is force fitted in the lower end of the cylindrical bore and extends to a point facing the radial passage 3. This member 9 is so shaped as to provide between itself and the bore an annular space 10 in which can engage a skirt 11 constituting a lower portion of the movable core 8. This latter has a longitudinal passage 12 in which is disposed a coil compression spring 13, whose one end bears against a washer 14 force fitted in core 8, its other end bearing against the head 15 of a rod 16 carried by fixed core 7.
The longitudinal passage 12 establishes communication between the space 17 comprised between the two magnetic cores and the space 18 comprised between the movable core 8 and the cylindrical member 9. Thus, the static pressure exerted on the two ends of the movable core 8 is the same, such that there is no hydraulic force resultant acting on this core 8.
It should also be noted that the cylindrical member 9 has three vertical passages 19 placing in communication the two passages 2 and 3 when the movable core 8 is drawn toward the fixed core 7. As is shown in FIG. 1, a portion 20 of member 9 constitutes a deflector above passage 19, such that the fluid passing through passage 2 toward passage 3 is directed radially against the lower part of skirt 11 and accordingly exerts no dynamic pressure on this latter.
Member 9 is so shaped as to provide an annular groove 21 just below the skirt 11, this groove communicating by a passage 22 with space 18, which helps equalize the fluid pressures.
It should be noted that the two confronting surfaces of the fixed core and the movable core have two recesses 23 and 24 and two projecting portions 25 and 26 adapted to enter said recess, so as to obtain a force of magnetic attraction between the cores which will be substantially constant over a major portion of the path of the movable core 8. It will also be noted that the depth of one of these recesses 23 24 is different from that of the other, while the height of the projecting portions 25 and 26 correspond substantially to the respective depths of the recesses, such that in the course of attraction of the movable core the two projecting portions 26 and 27 will be engaged in the two recesses 23 and 24.
FIG. 3 shows the magnetic attraction force F as a function of path D of the movable magnetic core. The curve a represents substantially the force due to the magnetic field produced between the projecting portion 25 and the recess 23, while the curve b corresponds to the force due to the magnetic field prevailing between the projecting portion 26 and the recess 24. These two curves each have a weaker attraction portion a1 and b1 respectively, which occur when the projecting portions penetrate the recesses and the principal magnetic field is then directed in a direction radial to the two cores and therefore does not contribute to the force of magnetic attraction in the direction of displacement of the movable core. The curve c shows the addition of the attractive forces according to the curves a and b and has a portion comprised between the points d1 and d2 corresponding to a substantially constant attractive force.
It is advantageous so as to obtain fine adjustment of the fluid flow, to feed the excitation winding 5 with current pulses delivered by a source at a frequency higher than the natural oscillation frequency resulting from the mass of the core 8 and the return force of the spring 13. In practice, good results were obtained with substantially rectangular pulses of a frequency of the order of 400 Hz. A variable cyclic and periodic relationship can be superposed on these pulses, this cyclic relationship being adapted to give frequencies such as 38-42-38-42. . . Hz. This produces a vibration of the core which prevents its sticking in the bore.
FIG. 4 shows a modified embodiment in which the cylindrical member 9 has no passage 22, the communication between the annular groove 21 and the space 18 being achieved by passages 27 provided in the skirt 11' which is constituted by a member secured to the hub 8.
In the two illustrated examples, the obturation of the fluid passage is effected by the external surface of the skirt 11 which bears against the internal surface of the cylindrical bore in which the core 8 moves. However, it could also be arranged that the skirt 11 bears by its internal surface against the external surface of the cylindrical member 9.
Of course numerous modifications of form can be provided and particularly the projecting portions 25 and 26 could be a part of one or the other of the two cores 7 and 8 respectively. These projecting portions and these recesses need not necessarily be of circular section, although this is the shape that is easiest to machine. | The electromagnetic valve comprises a movable core (8) adapted to be drawn toward a fixed core (7) under the influence of a magnetic field of an excitation winding (5). The lower portion of the core (8) has a skirt (11) surrounding a cylindrical member (9) which is shaped such that the fluid moving from passage (2) to passage (3) will be directed radially relative to the skirt (11), so as to avoid the exertion of a force on the core (8) in its direction of movement. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to differentials, particularly to a limited slip differential applied to a vehicle.
2. Description of the Related Art
Differentials are well-known mechanisms and comprised of means to adequately transfer rotational torque when there are differences on rotational speeds between the opposite output axle shafts of wheels on the vehicle. A conventional mechanical differential includes two planetary gears meshing with side gears on two output shafts, whereby the planetary gears are significantly driven according to the different rotational speed between the side gears. When the wheels rotate on different road engagements to produce different rotational speed, the conventional differential is passively triggered without restricting rotations of the two axle shafts. Once the vehicle is driven on a humid or greasy road to cause the wheel slipped or soared, the slipped wheel idly rotates and the other wheel loses the supported dynamic torque imparted from the vehicle as well, thence rendering the vehicle unable to formally operate. To improve the existences of idle rotation or the lack of the dynamic torque, various limited slip differentials (LSD) are produced afterward. The main LSDs commonly include a clutch-type mechanical LSD, a torque sensitive LSD relying on frictions between helical gears, a clutch LSD configured of multiple discs and shafts for a mutual interlocking via a pressure ring squeezing the discs, and a viscous coupling type LSD relying on silicon-based oils with high viscosity to compress stacks of clutch discs under a heat expansion and create a hydrodynamic friction for coupling the discs. Whereas, deficiencies attendant on the differentials are complex structures, an uneasy repairing and maintenance, and an effective operation under a large speed difference.
SUMMARY OF THE INVENTION
The objective of the present invention is to offer a limited slip differential benefiting a convenient installation and maintenance without complicate parts for decreasing costs, efficiently adjusting a rotational speed difference, and attaining a limited-slip effect.
The limited slip differential adapted to a vehicle in accordance with the present invention mainly comprises a sealed differential casing containing fluid, a driving plate disposed in the accommodating space, two backing plates pivotally connected with both sides of the driving plate, a plurality of differential gear assemblies disposed on the driving plate and a transmission assembly synchronized with the gear assemblies. Wherein, the driving plate includes a plurality pairs of openings and each pair is in communication, so that two differential gears of each gear assembly would interlock and rotatively mesh with each other. The two gears respectively penetrate through the correspondent openings and holes for separately engaging with two planetary gears and sun gears of the transmission assembly; each backing plate further provides holes disposed relatively to the above openings for traveling the fluid through the interstices between the two differential gears. Each sun gear includes an axis oppositely pivoted to the driving plate and extended to an axle shaft of the vehicle. Accordingly, the present invention needs not complicated components for attaining a convenient assemblage and maintenance. Moreover, when the vehicle simultaneously drives the transmission assembly along with the above plates, the differential gear assemblies are triggered to promote a mutual rotating relationship so as to adjust the rotational speed of the axle shafts. In the event that a rotational speed difference between the axes of the sun gears driven by the vehicle exceeds a predetermined threshold, at least one differential gear assembly immediately delivers a back pressure to avoid seeping the fluid between the two differential gears, and then the two meshed gears would stop rotating to prevent from enlarging the rotational speed difference. Thus, the LSD efficiently benefits a limited-slip effect as well.
The advantages of the present invention over the prior arts are more apparent by reading following descriptions with drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view showing a first preferred embodiment of the present invention;
FIG. 2 is a schematic view of the first preferred embodiment;
FIG. 3 is an exploded view showing of FIG. 1 in assemblage;
FIG. 4 is a side view showing of FIG. 3 ;
FIG. 5 is a side view of a modification of the first embodiment;
FIG. 6 is a side view of another modification of the first embodiment;
FIG. 7A-7B are graph views of the operation of the present invention;
FIG. 8 is a schematic view showing a second preferred embodiment;
FIG. 9 is a schematic view showing a third preferred embodiment;
FIG. 10 is a side view showing of FIG. 9 ; and
FIG. 11 is a schematic view showing a fourth preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing in details, it should note the like elements are denoted by similar reference numerals throughout the disclosure.
Referring to FIGS. 1 and 2 shows a limited slip differential (LSD) 10 of the first preferred embodiment adapted to a vehicle (not shown) comprising a differential casing 11 , a driving plate 12 disposed within the differential casing 11 , two backing plates 13 respectively attached to both sides of the driving plate 12 , a plurality of differential gear assemblies 14 mounted on the driving plate 12 , and a transmission assembly 15 engaged and synchronized with the differential gear assemblies 14 . Wherein, the differential casing 11 is interlocked to form a sealed room, in which a shared accommodating space 111 is defined to contain fluid. Further, the driving plate 12 is placed within the accommodating space 111 for partially soaking in the fluid, which further includes an inserting bore 121 and pairs of openings 122 substantially disposed around the inserting bore 121 ; three pairs of openings 122 are adopted herein; each pair of the openings 122 is comprised of a first opening 1221 juxtaposed and communicated with a second opening 1222 . Additionally, each pair of the openings 122 has both sides thereof forms respective troughs 123 , and each trough 123 through the driving plate 12 communicates with any two adjacent openings 122 . Furthermore, the driving plate 12 provides with a series of gear teeth 124 formed on the periphery thereof and stick them out of the circumference of the two backing plates 13 . In the event the gear teeth 124 is offered, a driving gear 16 is adequately disposed within the differential casing 11 to interlock with the gear teeth 124 and comprised of a driving shaft 161 protruding out of the differential casing 11 for pivoting to a power source 20 of the vehicle.
The backing plates 13 respectively provide the inner sides thereof fastening to both sides of the driving plate 12 for synchronizing therewith and each comprises an inserting orifice 131 and a plurality of holes 132 spaced apart around the inserting orifice 131 ; the holes 132 are disposed correspondently to the first and second openings 1221 , 1222 . Moreover, the backing plate 13 also defines a plurality of apertures 133 located correspondently to the troughs 123 on the driving plate 12 and blockers 1331 discretely disposed outside the apertures 133 and orientated toward a center of the backing plate 13 , whereby the fluid sequentially passes through the apertures 133 , the holes 132 , the troughs 123 , and thence into the openings 122 via the blockers 1331 . Furthermore, the gear assemblies 14 are accommodated into relative openings 122 of the driving plate 12 and the gear shafts thereof would thence go through the holes 132 of the backing plates 13 . Herein, three gear assemblies 14 are adopted. Each differential gear assembly 14 has a first differential gear 141 embedded into the first opening 1221 of the driving plate 12 and a second differential gear 142 located within the second opening 1222 , so that the first differential gear 141 significantly meshes with the second differential gear 142 for permitting the fluid to enter interstices between respective edges thereof through the openings 122 and the holes 132 . Furthermore, the first and second differential gears 141 , 142 have respective extensions oppositely extending from the driving plate 12 , namely, the first differential gear 141 has a first extension 1411 protruding to one side (e.x. right side), and the second differential gear 142 provides with a second extension 1421 protruding oppositely to where the first extension 1411 extends (e.x. left side) for respectively connecting with the transmission assembly 15 .
Still referring to FIG. 1 , the transmission assembly 15 engages with the differential gear assemblies 14 for synchronizing therewith and includes two sets of planetary gears 151 respectively disposed on both exterior sides of the two backing plates 13 and two sun gears 152 separately meshing with the planetary gears 151 ; wherein, the planetary gears 151 respectively comprise a first planetary gear 1511 and a second planetary gear 1512 . The two planetary gears 151 could be as substantive configurations, whereby the first and second differential gears 141 , 142 provided with the extensions 1411 , 1421 penetrating through the correspondent openings 122 and holes 132 for separately engaging with the first and second planetary gears 1511 , 1512 , which thence mesh with respective sun gears 152 in FIGS. 3 and 4 . Alternatively, FIG. 5 shows the first and second planetary gears 1511 , 1512 are integrated with respective gear shafts of the first and second differential gears 141 , 142 , so that the differential gears 141 , 142 directly mesh with the sun gears 152 . In preferred embodiments, the configuration of FIG. 1 is herein adopted.
Referring to FIGS. 4 and 5 , two sun gears 152 essentially mesh their exterior teeth with an outer periphery of the first and second planetary gears 1511 , 1512 , or the sun gears 152 may have interior teeth 1521 meshing with an outer periphery of the first and second planetary gears 1511 , 1512 as shown in FIG. 6 . Still referring to FIG. 2 , Each sun gear 152 has an axis 1522 provided with one side thereof fastening to the inserting bore 121 of the driving plate 12 through the inserting orifice 131 of the backing plate 13 and with the other side thereof protruding out of the differential casing 11 for mounting on two axle shafts 21 of the vehicle, therefore the driving plate 12 , the backing plates 13 , the differential gear assemblies 14 and the transmission assembly 15 are firmly assembled to accomplish a complete LSD 10 . It should also noted that the differential gear assemblies 14 , planetary gears 151 , and the sun gears 152 could be used by either a spur gear, a helical gear, or a double-helical gear.
Referring to FIGS. 1 and 2 , while in assemblage, the fluid (e.x. oil or grease) is pumped into the shared accommodating space 111 in an adequate proportion. While operating, a power source 20 of the vehicle initially delivers a dynamic torque to the driving shaft 161 to rotate the driving gear 16 and then the gear teeth 124 , and simultaneously the vehicle axle shafts 21 are driven by the vehicle wheels (not shown) to rotate the axes 1522 of the sun gears 153 . The driving plate 12 and the backing plates 13 would synchronically become revolutions as well. Accordingly, the planetary gear 151 along with the gear assembly 14 rotates and soaks into fluid in turn. Even one of gear assemblies 14 leaves the fluid during the revolution and rotation, the fluid inside the gear assembly 14 would still flow downward through the trough 123 into the adjacent first and the second openings 1221 , 1222 . The fluid remaining on the surfaces of the two backing plates 13 is introduced into the apertures 133 via the obstruction of the blocks 1331 to enter into the adjacent openings 1221 , 1222 as well, and thereafter the gear assembly 14 would immerse into the fluid again, so that every gear assembly 14 is soaked with fluid on their surfaces and a volume of fluid delivery indicating the quantity of the fluid entering each differential gear assembly 14 is created.
In this manner, when the vehicle drives forward or backward directly, every differential gear assembly 14 synchronically revolves with the driving plate 12 and the backing plates 13 attributably to the axle shafts 21 having the same rotational speed, therefore no mutually rotating relationship is occurred, namely the meshed first and the second differential gears 141 , 142 , the axes 1522 of the sun gears 152 on the axle shafts 21 , the first and second planetary gears 1511 , 1512 , the driving plate 12 , and the backing plates 13 are in a same revolution, and the LSD 10 does not restrict the rotating speed of the vehicle wheels. While turning the vehicle, the axle shafts 21 along with the two axes 1522 on vehicle wheels (right and left) inevitably provide different revolution speeds relying to the different required rotation distance, which thence generates a rotational speed difference. Thus, the axes 1522 respectively motivate a relative motion of the differential gear assemblies 14 , by which each of meshed differential gears 141 and 142 have different rotation speed and either of which relatively rotates faster than the other one. A specified volume of the fluid release traveling through the interstices between edges of the gears 141 , 142 is preferably created. Further shown in FIG. 7A , in the even that the rotational speed difference |ω R −ω L | on the axes 1522 of the two side wheels of the vehicle is smaller than a predetermined threshold (e.x. 50 rpm/min) to render the volume of fluid delivery to be smaller than the volume of fluid release, the first differential gear 141 becomes meshing rotatively with the second differential gear 142 because the fluid is permissibly traveled through the interstices between the edges of the first and second gears 141 , 142 for promoting a mutual motion thereof, so as to attain the merit of the speed limitation and conduce propitiously turning the vehicle.
When the vehicle has either of the wheels slipped or soared on a defected road condition (e.x. on a humid ground or a non-level ground), the rotational speed difference between the axle shafts 21 and the two axes 1522 accordingly expands. As long as the rotational speed difference |ω R −ω L | of the axes 1522 exceeds the predetermined threshold (e.x. 50 rpm/min), the LSD 10 increases the volume of fluid delivery, and such transient fluid delivery sets above the volume of fluid release to render at least one differential gear assembly 14 unable to instantaneously drain the fluid through the first and second gears 141 , 142 . Thus, the differential gear assembly 14 promptly produces a back pressure as arrowed in FIG. 7B to create a limited torque T against the clockwise or counterclockwise rotations ω, which blocks the entry of the fluid into the interstices between the differential gears 141 , 142 . Via the limited torque T, the rotations of the first and second planetary gears 151 associated with the axes 1522 and axle shafts 21 are restricted as well, and the power source 20 would not transmit the dynamic torque to the slipped wheel in higher speed through the driving gear 16 . Instead, the power source 20 delivers more torque to the non-slipped wheel in lower speed for equilibrating the rotating velocity and restricting the expansion of the rotational speed difference (shown in FIG. 7A ), thereby supplying the non-slipped wheel with enough torque to smoothly propel the vehicle. The LSD 10 thus prevents the slippery idling of the vehicle and efficiently attains a limited-slip effect.
Consequently, by means of the differential gear assemblies 14 , the planetary gears 151 , and the sun gears 152 are constructed by standard parts, the LSD 10 also does not need a further molding for manufacturing and complex configuration as it could be facilely assembled via the aforementioned commercial parts for convenient repairing and maintenance. The present LSD 10 also utilizes the property of the fluid failing to travel through the interstices of at least one differential gear assembly 14 to concurrently adjust the rotational speed on wheels and decrease the slipped occurrence.
Referring to FIG. 8 shows a second preferred embodiment comprising elements similar to those of the first embodiment. Particularly, the driving plate 12 removes the gear teeth 124 and the driving gear 16 , whereas one of the backing plates 13 has a bevel gear plate 134 integrally extending from one side thereof, and the differential casing 11 accordingly disposes a bevel gear teeth 17 therein for meshing with and driving the bevel gear plate 134 ; the bevel gear teeth 17 also includes a shaft 171 projecting out of the differential casing 11 for being driven by the vehicle, so that the shaft 171 driven by the power source 20 of the vehicle would synchronically rotate the bevel gear plate 134 , the driving plate 12 , and the backing plates 13 . Further, the operations and effects of this embodiment are the same as the first embodiment and herein are omitted.
Referring to FIG. 9 shows a third preferred embodiment, in which the driving plate 12 and the two backing plates 13 are particularly devoid of the respective structures of the gear teeth 124 , the driving gear 16 , and the blockers 1331 . Instead, the differential casing 11 are firmly fastened to the backing plates 13 and a driving sheath 18 is pivoted to the differential casing 11 ; wherein, the driving sheath 18 comprises an outer covering 181 extensively encompassing the axes 1522 of the two sun gears 152 and a chain 182 on the outer covering 181 driven by a driving device 22 of the vehicle; additionally, each backing plate 13 includes a depression 135 defined on the outer surface thereof for defining a room between the backing plate 13 and the differential casing 11 , on which a plurality of holes 132 and apertures 133 are spaced apart in FIG. 10 .
Referring to FIGS. 9 and 10 , in operation, a power source 20 of the vehicle transmits a dynamic torque to the chain 182 through the driving device 22 (e.x. a sprocket associated with a catena), so that the outer covering 181 , the differential cashing 11 , the backing plates 13 , and the driving plate 12 synchronically rotate. When the vehicle is driven forward or backward, the axle shafts 21 on vehicle wheels have the same rotational speed for motivating the synchronous rotations of axes 1522 , the planetary gears 151 , the driving plate 12 , and the backing plates 13 for alternatively soaking the differential gear assemblies 14 into the fluid. Once the vehicle is turned to incur a rotational speed difference greater than a threshold, the fluid received within the room moves away from the center of the depression 135 under a centrifugal force and intensively enters the apertures 133 for significantly coating every differential gear assembly 14 with the fluid. Further, at least one gear assembly 14 acts to block the traveling of the fluid among the differential gears 141 , 142 and then limits the mutual motions of the two gears 141 , 142 to permit the vehicle to equally transmit the torque to both axes 1522 of the sun gears 152 . Therefore, this preferred embodiment also avoids enlarging the rotational speed difference via efficiently restricting the rotational speed and obtains a preferable limited-slip performance.
Referring to FIG. 11 , a fourth preferred embodiment comprises same elements in the first embodiment which is classified as a passive LSD (P-LSD) via motivating the different gear assemblies 14 to restrain the successive expansion of rotation speed on the transmission assembly 15 when the rotational speed difference exceeds than the threshold. Whereas, the fourth embodiment classified as an active LSD (A-LSD) especially appends an auxiliary power 23 (e.x. gear pump) to actively adjust the fluid flowing direction and the volume of fluid delivery sent to the differential gear assemblies 14 while turning the vehicle, thereby efficiently controlling the rotation speed of the vehicle wheels for the purposes of speed adjustment and limited-slip effect.
To sum up, the present invention takes advantage of placing a driving plate, backing plates, a transmission assembly, and differential gear assemblies into a sealed casing where fluid is stored, thereby sequentially immersing the differential gear assemblies into the fluid when the afore elements are synchronically rotated. Accordingly, the present invention mainly controls the entry of fluid flow via the mutual motion of the differential gears of each gear assembly for adjusting the rotational speed of the transmission assembly. When the axle shafts on vehicle wheels carry a current rotational speed difference greater than a threshold, at least one transmission assembly would produce a back pressure to block the fluid passing through the relative meshed gears, whereby the gears limit their mutual motion and render the vehicle to transmit a torque toward the non-slipped wheel to avoid enlarging the rotational speed difference and concurrently control the rotational speed as well as promote the limited-slip effect.
While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | A limited slip differential includes a driving plate, backing plates, differential gear assemblies, and a transmission assembly engaged together inside a sealed casing where fluid is pumped. The driving plate has pairs of communicated openings for interlocking two gears of each gear assembly, which extend by opposite directions from the driving plate for separately engaging with the transmission assembly. While synchronously rotating the plates, the gear assemblies are alternatively soaked into the fluid and each permits the fluid passing among the gears for adjusting the rotational speed. In the event that the rotational speed difference of axle shafts of the vehicle exceeds a threshold value, the LSD applies at least one gear assembly to generate a back pressure and efficiently block the fluid passing through the gears for limiting mutual rotational speed difference, hence achieving a limited-slip effect. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application 62/056,307, filed Sep. 26, 2014 by Aytac AZGIN, et. al., and entitled “METHOD AND SYSTEM FOR HASH-BASED FORWARDING FOR CONTENT CENTRIC NETWORKS”, which is incorporated herein by reference as if reproduced in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
BACKGROUND
In content centric networks (CCNs), a domain-wide unique name is assigned to each entity that is part of a content delivery framework. CCN entities may include data content, such as video clips or web pages, and/or infrastructure elements, such as routers, switches, or servers. In a CCN, content routers are responsible for routing user requests and content to recipients. The content routers mute packets based on name prefixes, which may be full content names of name prefixes of content names, instead of network addresses. Content delivery, such as publishing, requesting, and managing of the content, is based on the name of the content instead of the location of the content. CCNs differ from Internet Protocol (IP) networks by performing in-network content caching, which may be on a temporary basis or a more persistent basis. This may allow content to be served from the network instead of an original content server, and thus may substantially improve user experience. The cached content may be used for real time data that is fetched by the user or for persistent data that belongs to the user or to a content provider, for example, a third party provider.
SUMMARY
In one embodiment, the disclosure includes a method implemented by a network element (NE), comprising obtaining a first mapping between a first content name identifying a content data in a CCN and a first hash value of at least a portion of the first content name, wherein the first content name comprises a character string in a hierarchical namespace, receiving, via a receiver of the NE, an initial packet comprising an initial hash value from the CCN, determining, via a processor the NE, that the initial hash value in the received initial packet matches the first hash value in the obtained first mapping, replacing, via the processor, the initial hash value in the received initial packet with the first content name in the matched first mapping to produce a translated initial packet, and forwarding, via a transmitter of the NE, the translated initial packet comprising the first content name to a connected end host.
In another embodiment, the disclosure includes an NE comprising a port configured to couple to a CCN, a memory configured to store a hash table comprising a bucket entry indexed by a bucket index, wherein the bucket entry comprises a sub-entry indicating the port as an interface associated with a first hash-based content identifier (ID) comprising a first hash value, and a processor coupled to the memory and the port, wherein the processor is configured to receive a packet comprising a second hash-based content ID comprising a second hash value, locate the bucket entry in the hash table by determining that at least a first portion of the second hash value matches the bucket index, determine that at least a portion of the second hash-based content ID in the received packet matches the first hash value in the sub-entry of the located bucket entry, and forward the received packet to the CCN via the port indicated in the matched sub-entry.
In yet another embodiment, the disclosure includes a name resolution server (NRServ) comprising a receiver configured to receive a content registration request message requesting registration for a first content name in a CCN, wherein the first content name comprises a hierarchical structure in a namespace and a character string, a processor coupled to the receiver and configured to generate a hash-based content ID by applying a first hash function to the first content name, wherein the hash-based content ID comprises a same hierarchical structure as the first content name in a hash-space, and a transmitter coupled to the processor and configured to send a content registration response message indicating the hash-based content ID for the first content name in response to the received content registration request message.
These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
FIG. 1 is a schematic diagram of an embodiment of a CCN architecture.
FIG. 2 is a schematic diagram of an embodiment of a hash-based forwarding CCN architecture.
FIG. 3 is a schematic diagram of an embodiment of an NE within a CCN.
FIG. 4 is a protocol diagram of an embodiment of a method for performing hash-based forwarding in a CCN.
FIG. 5 is a schematic diagram of an embodiment of a scheme for transforming a content name to a hash-based content ID.
FIG. 6 is a schematic diagram of an embodiment of a scheme for storing and searching a hash-based forwarding table.
FIG. 7 is a schematic diagram of an embodiment of a scheme for extracting content name information from a hash-based content ID
FIG. 8 is a flowchart of an embodiment of a method for performing hash-based forwarding.
FIG. 9 is a flowchart of another embodiment of a method for performing hash-based forwarding.
FIG. 10 is a table comparing average pending interest table (PIT) and forwarding information base (FIB) storage requirements of various storage schemes.
FIG. 11 is a graph comparing PIT and FIB storage performance of various storage schemes.
FIG. 12 is a graph comparing line rate performance of various storage schemes with static random-access memory (SRAM) storage devices.
FIG. 13 is a graph comparing line rate performance of various storage schemes with reduced latency-dynamic random-access memory (RL-DRAM) storage devices.
FIG. 14 is a graph illustrating improvement in processing overhead and network capacity from the employment of a name-based forwarding scheme to a hash-based forwarding scheme.
DETAILED DESCRIPTION
It should be understood at the outset that, although illustrative implementations of one or more embodiments are provided below, the disclosed systems and/or methods may be implemented using any number of techniques, whether currently known or in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
FIG. 1 is a schematic diagram of an embodiment of a CCN architecture 100 . The CCN architecture 100 comprises a CCN controller 110 , and a CCN 150 . The CCN 150 comprises a plurality of NEs acting as content nodes 130 and/or other NEs, such as content producers and/or content consumers, interconnected by a plurality of links 140 . The CCN 150 provides in-network caching, built-in content security, and multi-cast data distributions according to the CCN protocol. The CCN 150 may comprise one or more networking domains that are operated by one or more administrative domains. The links 140 may comprise physical links, such as fiber optic links, electrical links, wireless links, and/or logical links used to transport data in the CCN 150 .
The CCN controller 110 may be any device configured to manage and/or control the CCN 150 . The CCN controller 110 may be physically or logically located within the CCN 150 . In an embodiment, the CCN controller 110 may be a centralized logical entity distributed across one or more NEs. In another embodiment, the CCN controller 110 may be implemented as a network control module within a virtual machine (VM). The CCN controller 110 performs a variety of network control functions according to the application-specific objectives. Some examples of network control functions may include, but are not limited to, generating and maintaining network topologies, identifying application flows, and managing network resources and network state information.
To deliver content through the CCN 150 , the CCN controller 110 generates flow rules by computing one or more forwarding paths through the CCN 150 and identifies controls based on any application, content, or domain specific objectives. Some examples of controls may include security verifications and enforcements, context adaptations, content caching, and policy enforcements. After identifying the flow rules, the CCN controller 110 generates a flow entry based on the flow rules and adds the flow entry in each of the content nodes 130 along the forwarding path, for example, by sending the flow entry in a flow configuration message via a network control interface 120 . The network control interface 120 supports communication between the CCN controller 110 and the content nodes 130 and may employ a standard communication protocol and/or extend a current communication protocol, such as the OpenFlow protocol.
The CCN controller 110 builds and maintains a global network topology view of the CCN 150 based on the flow rules identified in the CCN 150 , where the global network topology view is an abstracted view of the underlying infrastructure of the CCN 150 . For example, the global network topology view may include network resources, (e.g., bandwidth usage, bandwidth availability, and/or latencies), network statistics, and/or application statistics in addition to network connectivity information (e.g., interconnecting NEs and/or links).
The content nodes 130 may be any physical devices, such as routers and/or network switches, or logical devices configured to perform switching functions in the CCN 150 as directed by the CCN controller 110 . The switching functions include forwarding incoming interest packets based on entries in the FIB, applying flow rules to the incoming packets, measuring statistics, and monitoring context changes.
The content nodes 130 receive flow rules from the CCN controller 110 , such as forwarding paths for content flow in the CCN 150 . The content nodes 130 maintain and track the received flow paths in FIBs. Entries in the FIB comprises content name prefixes and corresponding outbound port(s) or coupled to a next hop within the CCN towards a corresponding content producer.
To obtain a particular content item, a content consumer creates an interest packet and sends the interest packet through the CCN 150 . The content item may be identified using hierarchically structured names that represent relationships between the different content items within the CCN 150 . These names comprise any number of components where each component identifies a portion of the namespace hierarchy. The interest packet comprises a content name for the particular content item. The interest packet is routed through the CCN by the content nodes 130 toward the producers of the requested content item based on the content name.
When a content node 130 within the CCN 150 receives an interest packet, the content node 130 determines where to forward interest packet by applying a longest name prefix matching (LPM) on the provided content name. This process is repeated at each content node 130 until the interest packet is delivered to the content producer or content repository (e.g., content node 130 carrying the requested content). When the interest packet reaches a node within the CCN 150 that has the requested content, a data packet comprising the content and the content name is built and returned back to the consumer through the CCN 150 along the same path traveled by the interest packet. This return path is based on state information set up by content nodes 130 that forwarded the corresponding interest packet. Both the interest and data packets may not carry any host or interface addresses.
The content nodes 130 within the CCN 150 keep both interests and data packets for a period of time. When a content node 130 receives multiple interest packets for the same content, the content node 130 forwards only the first interest packet received towards the content producer. The content node 130 stores information of the received interest packets in a PIT for a defined period of time or until a corresponding data packet is received. An entry in the PIT comprises the requested content name and the interest packet origin (e.g., the previous hop). When the content node 130 receives a data packet, the content node 130 forwards the data packet based on all active PIT entries for the received content. The PIT entries are removed once satisfied and the content node 130 caches the received content in a CS. The content node 130 may employ the content cached in the CS to satisfy any received interest packet without forwarding the interest packet.
As described above, CCNs, such as the CCN 150 , identify entities by hierarchical names or name prefixes (e.g., /domain/host/content) and rely on stateful name-based forwarding to pull content from the content producer. In addition, content nodes, such as the content nodes 130 , in the CCNs employ PITs to store interest packet information, FIBs to store outgoing interface information, and content stores (CSs) to cache contents, where the PITs, the FIBs, and the CSs also store associated content names. However, the hierarchical names are unbounded names, which may carry any number of name components and each name component may comprise any number of characters. The unbounded names may lead to large transmission overheads and consuming bandwidth unnecessarily. In addition, the unbounded names may lead to large storage requirements at the content nodes for the PITs, the FIBs, and the CSs. Further, the searching of the PITs, the FIBs, and the CSs based on the unbounded content names may be inefficient. For example, the PITs, the FIBs, and the CSs may be indexed by hashes of the content names. Thus, hash computations are required for performing the search, where hash computations may be expensive.
Disclosed herein are various embodiments for efficiently performing hash-based forwarding in a CCN by transforming content names from a namespace to a hash-space to produce hash-based content IDs. A namespace content name comprises an unbounded length of character string, whereas a hash-based content ID is composed of hash values, which are bounded in length and may comprise a significantly shorter average length. In a hash-based forwarding CCN, interest packets are embedded with hash values identifying requested contents and data packets are embedded with hash values identifying the contents in the data packets. The disclosed embodiments employ one or more NRServs to compute hashes for content names in the CCN. The disclosed embodiments enable end hosts (e.g., producers and consumers) of the CCN to publish and/or request contents based on content names by employing edge routers to translate packets between name-space and hash-space. The edge routers that are connected to the end hosts are referred to as ingress points or service points. For example, a service point may obtain mappings between content names and hash-based content IDs from the NRServs and store the mappings in a local database. Upon receiving a packet carrying a hash-based content ID from the CCN, the service point replaces the hash-based content ID in the received packet with a corresponding content name according to the local database prior to forwarding the packet to an end host. Conversely, upon receiving a packet carrying a content name from an end host, the service point replaces the content name in the received packet with a corresponding hash-based content ID according to the local database prior to forwarding the packet in the CCN. In an embodiment, content names are transformed into hash-based content IDs by applying a hash function, such as a cryptographic hash function, to each name prefix of the content name and aggregating the hashes of the name prefixes. Thus, the CCN hierarchical name structure is preserved in the hash-based content IDs. In addition, FIB searches may be performed based on LPMs as in the name-based forwarding scheme.
Some advantages of employing hash-based forwarding over name-based forwarding may include efficient utilization of resources and elimination of hashing overheads at content routers. The hash-based forwarding scheme enables content nodes to store PITs, FIBs, and CSs based on bounded-length hash-based content IDs instead of unbounded-length name-base content IDs or content names, and thus reduces storage requirements at the content nodes. In addition, transmission overhead for packets carrying the shorter-length hash-based content IDs is smaller than packets carrying the unbounded-length content names. Further, the hash-based content IDs carried in the packets may be employed to directly index into the PITs, the FIBs, and the CSs during table lookups instead of computing hashes for the table lookups as in the name-based forwarding scheme, and thus reducing processing overhead at the content nodes and improving table lookup performance. Although the present disclosure described the embodiments based on end hosts that operate on content names, the disclosed embodiments are suitable for any end host formats since the conversion of content ID format is performed by the edge routers.
FIG. 2 is a schematic diagram of an embodiment of a hash-based forwarding CCN architecture 200 . The CCN architecture 200 comprises a CCN 250 and one or more NRServs 260 . The CCN 250 is structurally similar to the CCN 150 , but transports packets carrying hash representations of content names instead of the content names as in the CCN 150 . Hash representations of content names refer to the hash values generated from the content names based on a hash function. The hash representation of a content name is referred to as a hash-based content ID. As shown, the CCN 250 comprises a plurality of NEs 230 and a plurality of service points 231 , shown as SP_Pand SP_PC. The NEs 230 are similar to the content nodes 130 , but performs packet forwarding based on hash-based content IDs. In addition, the NEs 230 stores and indexes PITs, FIBs, and CSs based on the hash-based content IDs, where the storage structures and indexing schemes of the PITs, FIBs, and CSs are discussed more fully below. The service points 231 are similar to the NEs 230 , but may act as ingress points for one or more producers 271 and/or consumers 272 . As shown, the service point SP_PC 231 serves a consumer 272 , and the service point SP_PP 231 serves a producer 271 .
The NRServs 260 may be any physical devices or VMs configured to transform content names to hash-based content IDs. For example, the NRServs 260 may employ a 64-bit cryptographic hash function, which may provide additional security protection. The NRServs 260 maintain and track mappings between the hash-based content IDs and the content names in a local database. For example, upon receiving a content name registration request from a producer 271 , the NRSery 260 generates a hash-based content ID for the requested content name, stores a mapping between the content name and the hash-based content ID in the local database, and responds with the generated hash-based content ID and/or the mapping. Subsequently, the NRsery 260 may receive a hash mapping request for the content name from a service points 231 . In response, the NRsery 260 may provide a corresponding hash-based ID based on the mapping stored in the local database. In some embodiments, each NRSery 260 serves a subset of the NEs 230 and the service points 231 in the CCN 250 . In such embodiments, the NRServs 260 employ a global hash function and may coordinate with each other to provide mappings between hash-based content IDs and content names. In some other embodiments, a single NRSery 260 may serve all NEs 230 and service points 231 in the CCN 250 . In yet some other embodiments, the CCN 250 may be divided into multiple domains. In such embodiments, each domain may employ one or more NRServs 260 and may employ a different hash function.
To transform a content name, a hash function is applied to each name prefix of the content name and the hash values of the name prefixes are concatenated to form a hash-based content ID with the same hierarchical structure as the content name. For example, a content name represented by/domain/host/content comprises three name components and three name prefix levels. The three name components are /domain, /host, and /content. The three name prefixes are /domain, /domain/host, and /domain/host/content. The name prefix, /domain, is referred to as a first level name prefix or a minimum length name prefix. The name prefix, /domain/host/content, is referred to as a last level name prefix or a maximum length name prefix In some embodiments, the NRSery 260 may shorten the computed hash values for one or more of the name prefixes by extracting a portion of the computed hash values. The details of name-to-hash transformations are described more fully below.
The producer 271 may be a physical device, a VM, or an application that executes on a VM or a physical device configured to produce and publish contents in the CCN 200 based on content names. The consumer 272 may be a physical device, a VM, or an application that executes on a VM or a physical device configured to consume contents in the CCN 250 based on content names. In order to enable the producer 271 and the consumer 272 to operate based on content name, the service points 231 translates packets between content names and hash-based content IDs. For example, upon receiving a packet carrying a content name from the producer 271 or the consumer 272 , the service point 231 replaces the content name in the received packet with a corresponding hash-based content ID prior to forwarding the packet in the CCN 250 . Conversely, upon receiving a packet carrying a hash-based content ID from the CCN 250 , the service point 231 replaces the hash-based content ID in the received packet with a corresponding content name prior to forwarding the packet to the consumer 272 or the producer 271 . It should be noted that the computationally expensive hash computations are typically not performed at the service points 231 as the service points 231 consult with the NRservs 260 to obtain mappings between hash-based content IDs and content names. The service points 231 may store the name-to-hash mappings received from the NRservs 260 in local databases for fast lookups. In one embodiment, service points may be allowed to perform hash-based mappings based on locally existing information on the namespaces.
FIG. 3 is a schematic diagram of an embodiment of an NE 300 within a CCN, such as the CCN 250 . The NE 300 may be any component configured to act as a node such as the NRServs 260 , the CCN controller 110 , the NEs 130 and 230 , the service points 231 , the producer 271 , and the consumer 272 . NE 300 may be configured to implement and/or support the hash-based forwarding, storage, search mechanisms, or any other schemes described herein. NE 300 may be implemented in a single node or the functionality of NE 300 may be implemented in a plurality of nodes. One skilled in the art will recognize that the term NE encompasses a broad range of devices of which NE 300 is merely an example NE 300 is included for purposes of clarity of discussion, but is in no way meant to limit the application of the present disclosure to a particular NE embodiment or class of NE embodiments.
At least some of the features/methods described in the disclosure are implemented in a network apparatus or component such as an NE 300 . For instance, the features/methods in the disclosure may be implemented using hardware, firmware, and/or software installed to run on hardware. The NE 300 is any device that transports packets through a network, e.g., a switch, router, bridge, server, a client, etc.
As shown in FIG. 3 , the NE 300 may comprise transceivers (Tx/Rx) 310 , which may be transmitters, receivers, or combinations thereof. A Tx/Rx 310 may be coupled to plurality of downstream ports 320 for transmitting and/or receiving frames from other nodes and a Tx/Rx 310 may be coupled to plurality of upstream ports 350 for transmitting and/or receiving frames from other nodes, correspondingly. Upstream refers to the transmission direction towards a content source, whereas downstream refers to the transmission direction towards a content consumer.
A processor 330 may be coupled to each Tx/Rx 310 to process the frames and/or determine which nodes to send the frames to. The processor 330 may comprise one or more multi-core processors and/or memory devices 332 , which may function as data stores, buffers, etc. The processor 330 may be implemented as a general processor or may be part of one or more application specific integrated circuits (ASICs) and/or digital signal processors (DSPs). The processor 330 may comprise a hash-based forwarding processing module 333 , which may perform processing functions of a content node, an NRServ, a serve point depending on the embodiments and may implement methods 400 , 800 , and 900 , as discussed more fully below, and/or any other flowcharts, schemes, and methods discussed herein. As such, the inclusion of the hash-based forwarding processing module 333 and associated methods and systems provide improvements to the functionality of the NE 300 . Further, the hash-based forwarding processing module 333 effects a transformation of a particular article (e.g., the network) to a different state. In an alternative embodiment, the hash-based forwarding processing module 333 may be implemented as instructions stored in the memory devices 332 , which may be executed by the processor 330 . The memory device 332 may comprise a cache for temporarily storing content, e.g., a random-access memory (RAM). Additionally, the memory device 332 may comprise a long-term storage for storing content relatively longer, e.g., a read-only memory (ROM). For instance, the cache and the long-term storage may include dynamic RAMs (DRAMs), solid-state drives (SSDs), hard disks, or combinations thereof. The memory device 332 may be configured to store one or more FIBs, PITs, CSs, and name-to-hash databases.
It is understood that by programming and/or loading executable instructions onto the NE 300 , at least one of the processor 330 and/or memory device 332 are changed, transforming the NE 300 in part into a particular machine or apparatus, e.g., a multi-core forwarding architecture, having the novel functionality taught by the present disclosure. It is fundamental to the electrical engineering and software engineering arts that functionality that can be implemented by loading executable software into a computer can be converted to a hardware implementation by well-known design rules. Decisions between implementing a concept in software versus hardware typically hinge on considerations of stability of the design and numbers of units to be produced rather than any issues involved in translating from the software domain to the hardware domain. Generally, a design that is still subject to frequent change may be preferred to be implemented in software, because re-spinning a hardware implementation is more expensive than re-spinning a software design. Generally, a design that is stable and that will be produced in large volume may be preferred to be implemented in hardware, for example in an ASIC, because for large production runs the hardware implementation may be less expensive than the software implementation. Often a design may be developed and tested in a software form and later transformed, by well-known design rules, to an equivalent hardware implementation in an ASIC that hardwires the instructions of the software. In the same manner as a machine controlled by a new ASIC is a particular machine or apparatus, likewise a computer that has been programmed and/or loaded with executable instructions may be viewed as a particular machine or apparatus.
FIG. 4 is a protocol diagram of an embodiment of a method 400 for performing hash-based forwarding in a CCN, such as the CCN 250 . The method 400 is implemented between a producer, such as the producer 271 , a consumer, such as the consumer 272 , a NRserv, such as the NRSery 260 , a service point, shown as SP_P, such as the service point SP_P 231 , that serves the producer, and a service point, shown as SP_C, such as the service point SP_PC 231 , that serves the consumer. For example, the NRserv, the SP_P, and the SP_C, each employs a local database to store and track mappings between content names and hash-based content IDs. The method 400 is implemented when the producer publishes content and the consumer consumes the content. The method 400 illustrates a registration phase when the producer publishes the content and a forwarding lookup phase when the consumer pulls the content from the CCN. The method 400 assumes that the content is not cached when the consumer requests the content. In addition, the method 400 assumes that the SP_P and the SP_PC employs the same NRServ.
At step 405 , the producer sends a content registration request to the SP_P requesting registration of a content name in the CCN. The content name identifies a content produced by the producer. At step 410 , the SP_PP forwards the content registration request to the NRServ. At step 415 , upon receiving the content registration request, the NRSery generates a hash-based content ID for the content name by applying a hash function to the content name, as discussed more fully below. After generating the hash-based content ID, the NRSery stores a mapping between the content name and the hash-based content ID in the NRServ's local database. In some embodiments, the NRSery may apply more than one hash functions to a given namespace (e.g., the content name) and may store the hash functions associated with the given namespace in association with the mapping. At step 420 , the NRSery sends a content registration response to the SP_P indicating the content name and the generated hash-based content ID, In one embodiment, NRSery may also send the associated hash functions together with the content name and the generated hash-based content ID. At step 425 , upon receiving the content registration response, the SP_P generates an entry in the SP_PP's local database to store a mapping between the content name and the hash-based content ID in the received content registration response. At this time, the content name is registered in the CCN and the consumer may request for the content.
At step 430 , the consumer sends an initial name-based interest packet to the SP_PC indicating a requested content name. At step 435 , upon receiving the initial name-based interest packet, the SP_PC sends a hash mapping request to the NRSery indicating the requested content name. In some embodiments, the SP_PC may first check the SP_PC's local database for an entry matching the requested content name and sends the hash mapping request when a match is not found.
At step 440 , upon receiving the hash mapping request, the NRSery searches for an entry in the NRServ's local database with a content name matching the requested content name. At step 445 , when a match is found, the NRSery sends the hash-based content ID in the matching entry to the SP_PC. In some embodiment, when the SP_Pand the SP_PC are served by different NRserv, a match may not be found. Thus, the NRSery may communicate with other NRServs in the CCN to obtain the hash-based content ID for the requested content name.
At step 450 , after receiving the hash-based content ID, the SP_PC replaces the requested content name in the initial name-based interest with the received hash-based content ID to produce a hash-based interest packet. At step 455 , the SP_PC forwards the hash-based interest packet carrying the hash-based content ID to the SP_PP.
At step 460 , upon receiving the hash-based interest packet carrying the hash-based content ID, the SP_PP performs a reverse look up to search for an entry in the SP_PP's local database with a content name matching the hash-based content ID in the received hash-based interest packet. After finding a match, the SP_PP replaces the hash-based content ID in the received hash-based interest packet with the content name in the matching entry to produce a translated name-based interest packet. At step 465 , the SP_PP sends the translated name-based interest packet to the producer indicating the requested content by the content name. At step 470 , in response to the translated name-base interest packet, the producer sends an initial name-based data packet carrying the requested content identified by the content name.
At step 475 , upon receiving the initial name-based data packet, the SP_P searches for an entry in the SP_P's local database with a content name matching the content name in the initial name-based data packet. After finding a match, the SP_P replaces the content name in the received initial name-based data with the hash-based content ID in the matching entry to produce a hash-based data packet. At step 480 , in response to the hash-based interest packet, the SP_P sends the hash-based data packet to the SP_C.
At step 485 , upon receiving the hash-based data packet, the SP_C searches for an entry in the SP_C's local database with a hash-based content ID matching the hash-based content ID in the hash-based data packet. After finding a match, the SP_C replaces the hash-based content ID in the received hash-based data with the content name in the matching entry to produce a translated name-based data packet. At step 490 , the SP_C sends the translated name-based data packet to the consumer.
FIG. 5 is a schematic diagram of an embodiment of a scheme 500 for transforming a content name to a hash-based content ID. The scheme 500 is employed by an NRServ, such as the NRServs 260 , when the NRSery receives a content registration request from a producer indicating a content name 510 . The content name 510 comprises a sequential concatenation of k plurality of name components, shown as /c i /, where k is a positive integer and i is a value varying from 1 to k. For example, for a content name represented by /domain/host/content, id corresponds to /domain, /c 2 corresponds to /host, and /c 3 corresponds to /content. At step 551 , the content names are divided into k plurality of name prefixes 520 , shown as C i . For example, the content name /domain/host/content may be divided into three name prefixes 520 , a level one name prefix C 1 520 corresponding to /domain, a level two name prefix C 2 520 corresponding to /domain/host, and a level three name prefix C 3 520 corresponding to /domain/host/content. At step 552 , a hash function, shown as HF i (C i ), is applied to each level name prefix, C i , to produce a hash component 530 , shown as HC i , which is a hash value. The hash component 530 , HC i , may be referred to as a level i hash component. The hash function, HF i , may be a cryptographic hash function or any suitable hash function. At step 553 , the hash components 530 are concatenated in the same sequential order as the name prefixes 520 of the content name 510 to form a hash-based content ID 540 , shown as /HC 1 / HC 2 / . . . /HC k , which comprises the same hierarchical structure as the content name 510 .
In one embodiment, the hash function, HF i , is a 64-bit hash function when i is equal to 1 and a 32-bit hash function when i is a value between 2 to k. In such an embodiment, HC 1 is set to the full 64-bit hash value generated from HF 1 , and for 2≦i≦k, HC 1 is set to the full 32-bit hash value generated from HF i . In a second embodiment, the hash function HF i is a 32-bit hash function for all values of i between 1 to k. In such an embodiment, HC i is set to the full 32-bit hash value generated from HF i for all values of i between 1 to k. In a third embodiment, the hash function HF i is a 64-bit hash function for all values of i between 1 to k. In such an embodiment, HC 1 is set to the full 64-bit hash value generated from HF 1 , whereas for 2≦i≦k, HC i is set to a shortened version (e.g., a 32-bit portion) of the 64-bit hash value generated from HF i .
FIG. 6 is a schematic diagram of an embodiment of a scheme 600 for storing and searching a hash-based forwarding table 610 , such as a PIT, a FIB, or a CS. The scheme 600 is employed by a content node, such as the NEs 230 and the service points 231 , in a CCN, such as the CCN 250 . The table 610 may represent a PIT, a FIB, or a CS stored at the content node, for example, in a memory device, such as the memory device 332 . The scheme 600 assumes the employment of a 64-bit hash function for name-to-hash conversion. However, the scheme 600 may be employed with any hash function. The table 610 comprises a plurality of bucket entries 611 . Each bucket entry 611 comprises an index 612 , which is a hash value associated with a content name. For example, the index 612 is a first 32-bit portion of a 64-bit level one hash component HC 1 , such as the hash component 530 , of a hash-based content ID, such as the hash-based content ID 540 . Each bucket entry 611 further comprises a plurality of bucket sub-entries 613 comprising a 32-bit hash value 614 and a pointer 615 . The 32-bit hash value 614 is a second 32-bit portion of the 64-bit level one hash component, HC i . The pointer 615 references a sub-table entry 621 of a sub-table 620 . In an embodiment, when HC 1 is generated from a 32-bit hash function, the index 612 is set to HC 1 and the 32-bit hash value 614 is set to a transformation value, represented by HC 1 *, by applying a transform function to HC 1 , to produced HC 1 *. In another embodiment, the 32-bit hash value 614 may be a combination of a number of hash components of the hash-based content ID, as described more fully below.
The sub-table 620 comprises information associated with the hash component, HC 1 , or references to the information. When the table 610 represents a PIT, the sub-table 620 is associated with pending interest packets. For example, each sub-table entry 621 may comprise a full hash-based content ID of a pending interest packet, a nonce, an incoming interface (e.g., inbound port), and a timeout value. The full hash-based content ID refers to the aggregation of all hash components of a corresponding content name. When the table 610 represents a FIB, the sub-table 620 is associated with forwarding information. For example, each sub-table entry 621 may comprise a full hash-based content ID and corresponding outgoing interface information (e.g., outbound ports). When the table 610 represents a CS, each sub-table entry 621 stores a full hash-based content ID and a reference to corresponding content data. It should be noted that the bucket entries 611 , the sub-entries 611 in the bucket entries 611 , and the sub-table 620 may be configured as shown and described or alternatively configured as determined by a person of ordinary skill in the art to achieve similar functionalities. For example, content nodes, such as the NEs 230 and the service points 231 may independently organize the storages (e.g., with multiple level of sub-tables) for PITs, FIBs, and CSs and index the PITs, FIBs, and CSs by at least some portion of the level one hash component 641 , HC 1 .
A table lookup in the table 610 is based on 64-bit hash matching. For example, upon receiving a packet embedded with a hash-based content ID 640 from the CCN, a 32-bit portion of the level one hash component 641 , HC 1 , in the hash-based content ID 640 is directly employed to index into the table 610 to locate a bucket entry 611 , as shown by the dashed arrow 651 . The other 32-bit portion of HC 1 is employed to select a bucket sub-entry 613 in the located bucket entry 611 . Subsequently, the hash-based content ID 640 in the received packet is compared to the hash-based content ID in a sub-table entry 621 referenced by the selected bucket sub-entry 613 to determine a match. The structure of the table 610 may also be suitable for LPM in FIBs, as described more fully below.
FIG. 7 is a schematic diagram of an embodiment of a scheme 700 for extracting content name information from a hash-based content ID 710 similar to the hash-based content IDs 540 and 640 . The scheme 700 is employed by a content node, such as the NEs 230 and the service points 231 , in a CCN, such as the CCN 250 , to perform LPM for FIB lookup. As shown, a hash-based content ID 710 comprises k plurality of hash components 711 , shown as HC 1 to HC k , and an additional hash component 712 , shown as HC 1 *. The hash components 711 are similar to the hash components 530 . The additional hash component HC 1 * 712 is a transformation of the hash component HC 1 711 . The additional hash component HC 1 * 712 may be employed for sub-entry lookup or LPM when the hash component HC 1 711 is a 32-bit hash value. An LPM may be performed by merging two consecutive hash components 711 and 712 . For example, a first LPM check may concatenate the hash components HC k and HC k-1 711 , shown as 721 , to obtain a hash value for searching a FIB, which may comprise a structure similar to the hash table 610 and the sub-table 620 . The hash value may be compared against a hash value, such as the hash value 614 , in a FIB entry, such as the entry 613 . If no match is found from the first LPM check, a second LPM check may employ a concatenation of the hash components HC k-1 and HC k-2 711 , shown as 722 . If no match is found, the search may continue, where a last LPM may employ a concatenation of the hash component HC 1 711 and the additional hash component HC 1 * 712 , shown as 723 .
FIG. 8 is a flowchart of an embodiment of a method 800 for performing hash-based forwarding. The method 800 is implemented by a service point, such as the service point 231 and the NE 200 , in a hash-based forwarding CCN, such as the CCN 250 . The method 800 employs similar mechanisms as the method 400 . The method 800 is implemented when the service point forwards packets from a connected host the CCN. The connected host may be a producer, such as the producer 271 , that produces content in the CCN or a consumer, such as the consumer 272 , that consumes content in the CCN. The connected end host identifies content by content names, such as the content name 510 , in a hierarchical structured namespace, whereas routers, such as the NEs 230 , in the CCN routes packets by hash-based content IDs, such as the hash-based content IDs 540 , 640 , and 719 . At step 810 , a mapping between a first content name identifying a content data in the CCN and a first hash value of at least a portion of the first content name is obtained. For example, the first content name comprises a character string in the hierarchical structured namespace. The first hash value may correspond to one of the hash components, such as the hash components 530 , in a hash-based content ID corresponding to the content name. In one embodiment, the service point requests the mapping from an NRServ, such as the NRSery 260 . In another embodiment, the service point performs the mapping locally when the service point has previously received a mapping and/or a corresponding hash function associated with the first content name. For example, a producer may share a set of content names with a consumer. In order to avoid overloading the NRSery and reduce access latency, the NRSery may provide the service point with a hash function associated with the producer. Upon receiving a request from the consumer indicating one of the content names provided by the producer, the service point may compute a mapping for the content name locally according to the hash function.
At step 820 , an initial packet comprising an initial hash value is received from the CCN. At step 830 , a determination is made that the initial hash value in the received initial packet matches the first hash value in the obtained first mapping. At step 840 , the initial hash value in the received initial packet is replaced with the first content name in the first obtained first mapping to produce a translated initial packet. At step 850 , the translated first packet is forwarded to the connected end host indicating the content data by the content name.
In an embodiment, the connected end host is a producer of the content data and the received initial packet is an interest packet requesting for the content data. In such an embodiment, the first mapping between the first hash value and the first content name may be obtained from a content registration procedure initiated by the producer as described in the registration phase in scheme 400 . The service point may store the first mapping in a local database. In another embodiment, the connected end host is a consumer and the received initial packet is a data packet carrying the content data as described in the forwarding lookup phase in scheme 400 . In such an embodiment, upon receiving the initial packet, the service point may first check a local database for a match and send a hash mapping request to the NRsery when no match is found.
FIG. 9 is a flowchart of another embodiment of a method 900 for performing hash-based forwarding. The method 900 is implemented by a service point, such as the service point 231 and the NE 200 , in a hash-based forwarding CCN, such as the CCN 250 . The method 900 employs similar mechanisms as the method 400 . The method 900 is implemented when the service point forwards packets from the CCN to a connected end host. The connected end host may be a producer, such as the producer 271 , that produces content in the CCN or a consumer, such as the consumer 272 , that consumes content in the CCN. The connected end host identifies content by content names, such as the content name 510 , in a hierarchical structured namespace, whereas routers, such as the NEs 230 , in the CCN routes packets by hash-based content IDs, such as the hash-based content IDs 540 , 640 , and 710 . At step 910 , a mapping between a first content name identifying a content data in the CCN and a first hash value of at least a portion of the first content name is obtained, for example, from an NRServ, such as the NRSery 260 . For example, the content name comprises a character string in the hierarchical structured namespace. The first hash value may correspond to one of the hash components, such as the hash components 530 , in a hash-based content ID corresponding to the content name. At step 920 , an initial packet comprising an initial content name is received from the connected end host. At step 930 , a determination is made that the initial content name in the received initial packet matches the first content name in the obtained first mapping. At step 940 , the initial content name in the received initial packet is replaced with the first hash value in the obtained first mapping to produce a translated initial packet. At step 950 , the translated initial packet is forwarded in the CCN indicating the content data by the first hash value. In an embodiment, the connected end host is a producer of the content data and the received initial packet is a data packet carrying the content data. In another embodiment, the connected end host is a consumer and the received initial packet is an interest packet requesting for the content data.
FIG. 10 is a table 1000 comparing average PIT and FIB storage requirements of various storage schemes. The table 1000 compares average per PIT entry and per FIB entry storage requirements of a name-based storage scheme at a content node such as the content nodes 130 and a hash-based forwarding storage scheme at a content node such as the NEs 230 and the service points 231 . The name-based forwarding content nodes store content names, such as the content name 510 , in FIBs and PITs. The hash-based forwarding content node stores hash-based content IDs, such as the hash-based content IDs 540 and 640 , in FIBs and PITs comprising a similar storage structure as the hash table 610 and the sub-table 620 . The table 1000 compares the average per PIT entry and per FIB entry storage requirement when the interest packet size is about 60 bytes, about 80 bytes, and about 100 bytes. The table 1000 is generated based on numerical analysis assuming an average name component size of about 9 bytes. As shown, the per PIT and per FIB entry storage requirements at a hash-based forwarding content node is about 20 percent (%) less than a name-based forwarding content node. As such, the disclosed hash-based forwarding scheme reduces storage requirements at content nodes.
FIG. 11 is a graph 1100 comparing PIT and FIB storage performance of various storage schemes. In the graph 1100 , the x-axis represents storage capacities in units of megabytes (Mb), and the y-axis represents maximum number of entries in a linear logarithmic scale. The graph 1100 compares storage performance between a name-based storage scheme, a hash-based storage scheme, and an optimized hash-based storage scheme that limits hash-based content IDs, such as the hash-based content IDs 540 , 640 , and 710 , to a constant length, for example, about 128 bits. The name-based storage scheme is employed by a name-based forwarding content node, such as the content nodes 130 . The hash-based storage and the optimized hash-based storage scheme are employed by a hash-based forwarding node, such as the NEs 230 and the service point 231 . The graph 1100 is generated from numerical analysis assuming the employment of a fixed memory type, such as SRAM, for all storage schemes. The plots 1110 and 1111 show the maximum number of PIT and FIB entries supported as a function of memory size for the name-based storage scheme, respectively. The plots 1120 and 1121 show the maximum number of PIT and FIB entries supported as a function of memory size for the hash-based storage scheme, respectively. The plots 1130 and 1131 show the maximum number of PIT and FIB entries supported as a function of memory size for the optimized hash-based storage scheme. As shown, the PIT and FIB storage performances of the hash-based storage scheme and the optimized hash-based storage scheme are higher than the name-based storage scheme. As such, the disclosed hash-based forwarding scheme improves storage performance at content nodes such as the NEs 230 and the service points 231 .
FIG. 12 is a graph 1200 comparing line rate performance of various storage schemes with SRAM storage devices. In the graph 1200 , the x-axis represents various combinations of the number of components or name components and PIT sizes, and the y-axis represents maximum supported line rate in units of gigabits per second (Gbps). The graph 1200 compares line rate performance of a name-based storage scheme, a hash-based storage scheme, and an optimized hash-base storage scheme that limits hash-based content IDs, such as the hash-based IDs 540 , 640 , and 710 , to a length of about 128 bits. The line rate performance is determined from numerical analysis based on a PIT packet size of about 60 bytes. The bars 1210 , 1220 , and 1230 correspond to line rate performance for the name-based storage scheme, the hash-based storage scheme, and the optimized hash-based storage scheme, respectively. As shown, the hash-based storage scheme and the optimized hash-based storage scheme increase the line rate performance improvement when compared to the name-based storage scheme.
FIG. 13 is a graph 1300 comparing line rate performance of various storage schemes with RL-DRAM storage devices. In the graph 1300 , the x-axis represents various combinations of the number of components and the PIT sizes, and the y-axis represents maximum supported line rate in units of Gbps. The graph 1300 compares line rate performance of a name-based storage scheme, a hash-based storage scheme, and an optimized hash-base storage scheme that limits hash-based content IDs, such as the hash-based IDs 540 , 640 , and 710 , to a length of about 128 bits. The line rate performance is generated from numerical analysis based on a PIT packet size of about 60 bytes. The bars 1310 , 1320 , and 1330 correspond to line rate performance for the name-based storage scheme, the hash-based storage scheme, and the optimized hash-based storage scheme, respectively. As shown, the hash-based storage scheme and the optimized hash-based storage scheme provide a significant line rate performance improvement when compared to the name-based forwarding scheme. By comparing the graphs 1200 and 1300 , the RL-DRAM storage devices provide a significant higher line rate performance than the SRAM storage devices.
FIG. 14 is a graph 1400 illustrating improvement in processing overhead and network capacity from the employment of a name-based forwarding scheme to a hash-based forwarding scheme. The hash-based forwarding scheme employs similar mechanism as described in the method 400 and the schemes 600 and 700 . In the graph 1400 , the x-axis represents various combinations of memory types for storing PITs, the left y-axis represents percentile improvement in process overhead in units of %, and the right y-axis represents rate of improvement in network capacity. The graph 1400 is generated from numerical analysis. The following table lists the different combinations of memory types employed for the analysis:
TABLE 1
Combinations of Memory Types
Name-based Forwarding Scheme
Hash-based Forwarding Scheme
A
SRAM
SRAM
B
RL-DRAM
SRAM
C
RL-DRAM
RL-DRAM
D
DRAM
RL-DRAM
E
DRAM
DRAM
For example, a memory type combination BD shown in the x-axis refers to the employment of RL-DRAM for PIT storage and DRAM for FIB storage with the name-based forwarding scheme, and the employment of SRAM for PIT storage and RL-DRAM for FIB storage with the hash-based forwarding scheme. The improvement is obtained by comparing the hash-based forwarding scheme against the name-based forwarding scheme. The plot 1410 illustrates improvement in processing overhead. The plot 1420 illustrates improvement in network capacity. As shown, the improvement in processing overheads and network capacity varies with the types of memory under employment. For example, the processing overhead for the hash-based forwarding scheme is improved by about 26% to about 80% over the name-based forwarding scheme. The network capacity for the hash-based forwarding scheme is improved by about 2 times (shown as 1421 ) to about 5.47 times (shown as 1422 ) over the name-based forwarding scheme.
While several embodiments have been provided in the present disclosure, it may be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and may be made without departing from the spirit and scope disclosed herein. | A method implemented by a network element (NE), comprising obtaining a first mapping between a first content name identifying a content data in a content centric network (CCN) and a first hash value of at least a portion of the first content name, wherein the first content name comprises a character string in a hierarchical namespace, receiving, via a receiver of the NE, an initial packet comprising an initial hash value from the CCN, determining, via a processor the NE, that the initial hash value in the received initial packet matches the first hash value in the obtained first mapping, replacing, via the processor, the initial hash value in the received initial packet with the first content name in the matched first mapping to produce a translated initial packet, and forwarding, via a transmitter of the NE, the translated initial packet comprising the first content name to a connected end host. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is based on and hereby claims priority to German Application No. 10 2005 001 287.6 filed on Jan. 11, 2005, the contents of which are hereby incorporated by reference.
BACKGROUND
A method and a device for processing data, having basic information and elements with information supplementing the basic information, are described below.
In communication systems messages are transmitted between transmitters and receivers. A specific example of communication systems are radio communication systems. In radio communications systems messages such as signaling messages or user data messages with speech information, picture information, video information, SMS (Short Message Service), MMS (Multimedia Messaging Service) or other data for example are transmitted with the aid of electromagnetic waves over a radio interface between transmitting and receiving station. The stations can in this case, depending on the concrete embodiment of the radio communication system, be various types of subscriber-side radio stations, repeaters, or network-side radio stations such as base stations or radio access points. In a mobile radio communications system at least one part of the subscriber-side radio stations are mobile radio stations. The electromagnetic waves are emitted with carrier frequencies which lie in the frequency band provided for the relevant system.
Mobile radio communications systems are often embodied as cellular systems, in accordance with the GSM (Global System for Mobile Communication) or UMTS (Universal Mobile Telecommunications system) standard for example, with a network infrastructure including, for example, base stations, devices for checking and control of the base stations and further network-side devices. As well as these cellular, hierarchical radio networks organized on a wide-area (supralocal) basis, there are also Wireless Local Area Networks (WLANs) with a radio coverage area that as a rule is far more limited.
For the transmission of scalable information the basic information is transmitted, and in addition information which supplements the basic information. The characteristic of scalable data is thus that it can be present at the receiver in reduced quality, in that the receiver only decodes the basic information or the basic information and a part of the supplementary information, and not the basic information and all supplementary information. Data which is sent simultaneously to a number of subscribers can be present as scalable information at the sender in the best possible quality, i.e. as basic information and supplementary information. Before the data is transmitted or when it is being distributed in the network to the different receivers, an adaptation/scaling of the data is undertaken such that different parts of the supplementary information are forwarded to the different receivers, so that only the supplementary information needed by the respective receiver is transmitted. This proves advantageous especially with radio communication systems because of the scarce transmission resources.
SUMMARY
An aspect is to demonstrate a method and a device for processing scalable data.
In accordance with this aspect, the following are saved as a first dataset in a first order: Basic information and a plurality of elements containing information that supplements the basic information that increases the quality of the basic information during the decoding. The following is saved as a second dataset: Details about the position of the elements within the first dataset. The saved second dataset or a different dataset from the first and the second dataset contains information for converting the order of the elements from the first into the second order.
Both basic information and also supplementary information which increases the quality of the basic information exists when it is decoded in addition to the basic information. The basic information can also be decoded and processed without the supplementary information, it is not necessary for the supplementary information to be present for this to be done. The basic information and the supplementary information are both scalable information. When the scalable information is transmitted the transmission of the basic information preferably occurs before the transmission of the supplementary information.
The basic information and the supplementary information can be created by encoding data. The data can for example involve picture information, audio information, video information, which is encoded for example with an MPEG standard, speech information, or also a combination of these information types.
Two datasets are saved, which are separate from each other. The fact that two datasets are present means that the data of the first dataset and the data of the second dataset are not mixed when the data is read out from the datasets, if for example an amount of data of the first dataset is followed by an amount of data of the second dataset, after which comes data of the first dataset again. Thus the two datasets can be read out, without data of the other dataset in each case having to be read, the datasets are able to be read out separately. This can be implemented by the two datasets being saved as different files. The two datasets can be saved within the same or a different memory. The first and the second dataset can feature further content in addition to the content described.
The second dataset contains details about the position of the elements of the first dataset. This involves metadata since the data of the second dataset describes the data of the first dataset. The positions of the elements of the first dataset can be specified in relative terms, e.g. in relation to the position of another element, or also as absolute positions. The position can be specified by a pointer to the respective element. The specification of the position of an element enables access to this element, without other elements of the first dataset having to be read out or searched for.
Information for converting the order of the elements is present. This information can be held within the second saved dataset, or within another saved dataset different from the first and the second dataset. The dataset which differs from the first and the second dataset can be a dataset which is saved by the same device which also saves the first and the second dataset. Alternatively this dataset can be called by the device, which saves the first and the second dataset, or by another device.
In a specific order, elements have a particular sequence and where necessary a particular grouping. The second order can for example include leaving out of elements in relation to the first order or a particular grouping of elements. A reordering from the first into the second order can be implemented by leaving out elements from a particular element onwards, or through a rearrangement or new arrangement of the group elements with the sequence of the elements remaining the same or being changed.
The method can be applied in relation to a plurality of second orders.
The described method and further developments described below, are preferably executed by a device which includes a suitable memory such as an Internet server for example.
In a further development of the method, the stored second dataset contains further details about the way in which the supplementary information of the elements increases the quality of the basic information in each case. Thus a bitupel can exist within the second dataset for each element with supplementary information: the position specification and the specification of the way in which the quality is enhanced. This type of bitupel is preferably stored so that the position specification and the specification of the way in which the quality is enhanced are able to be read out directly after one another.
In particular the supplementary information can increase the quality of the basic information by increasing the temporal resolution and/or increasing the spatial resolution and/or improving the signal-to-noise ratio. The specifications can also contain quantitative details in relation to the improvement variables.
In an embodiment of the method, the order of the elements is converted from the first order into the second order and subsequently all or some of elements are sent. The reordering can in this case be used as a preparation for the transmission. The reordering and sending is preferably carried out by the same device that is responsible for the storage in accordance with the method or by a device that has access to a corresponding memory with the storage.
Preferably the information for conversion is determined from information which is sent from a future receiver of the basic information, and/or from information about the transfer of messages, especially the basic information, to a receiver. The information sent from a future receiver typically involves a specification relating to quality requirements of the receiver, equipment of the receiver or options or capabilities of the receiver for processing or outputting data. Information about the transfer of messages to a receiver can for example involve the traffic loading of a communication network which is responsible for the transport of the messages to the receiver, or the type of message transmission by this communication network.
The device for saving and processing data has means for saving basic information and a plurality of elements with information supplementing the basic information which when decoded increases the quality of the basic information, in a first order as first dataset, as well as means for saving details about the position of the elements within the first dataset as a second dataset. Furthermore means are present for storing within the saved second dataset or in a dataset which differs from the first and the second dataset information for converting the order of there elements of from the first into the second order or to call information for converting the order of the elements from the first into the second order.
A device on which data is encoded, may be used to save data in the manner described above and then sent, such as an Internet server for example. Such a device is especially suitable for executing the method in accordance with the invention, with this also being able to be applied to the embodiments and developments. To this end it can feature further suitable means.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages will become more apparent and more readily appreciated from the following description of an exemplary embodiment, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a three-dimensional view of a symbolic representation of the components of scalable data,
FIG. 2 is a data sequence diagram illustrating the saving of scalable data in a number of datasets,
FIG. 3 is a table showing the structure of an assignment table.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
The method explained below may be executed by an encoder, which can store, suitably prepare for sending and send the data encoded by it. An encoding of video information is considered as an example. The encoder considered is for example an Internet server. The encoder performs encoding of the video information, so that this is present as scalable data. Different components of scalable data are shown schematically in FIG. 1 . The block in the lower left corner of FIG. 1 corresponds to the basic information BASE. The further blocks, indexed by the variables T, B and S, correspond to the supplementary information. The T axis running to the right specifies how many images will be sent per unit of time, for example the first blocks to the right can correspond to a data rate of 7.5 fps (fps: frames per second), the second block to the right to a data rate of 15 fps and the third block to the right to a data rate of 30 fps. The S axis running upwards specifies how good the local resolution of the relevant image is, i.e. how many pixels an image contains, for example the first blocks upwards can corresponds to QCIF (Quarter Common Intermediate Format, this is equivalent to an image size of 176×144 pixels), the second blocks upwards CIF (Common Intermediate Format, this is equivalent to an image size of 352×288 pixels and the third blocks upwards 4CIF (4 times Common Intermediate format, this is equivalent to an image size 704×576 pixels). The B axis running backwards specifies the signal-to-noise ratio (SNR) of an image. This means that the temporal resolution of the video information increases to the right, the spatial resolution upwards and the signal-to-noise ratio backwards. Each block of FIG. 1 contains the data which is needed to improve the visual quality by one stage in a direction of the three scalability dimensions.
The method can also be applied to still images. In this case only two dimensions exist instead of the three scalability dimensions of FIG. 1 , the T axis is omitted. The method is also suitable for use with audio information. The use of a different number of scalability dimensions or other scalability dimensions compared to FIG. 1 in relation to video or other information is conceivable within the framework of the method.
It is basically sufficient for a receiver to receive and decode the basic information BASE, but this information is not of high quality. To enable it to display the video information, the user equipment must at least decode the basic information BASE. The decoding of each further block of FIG. 1 in addition to the basic information BASE improves the quality of the video information. Depending on the encoding method used, the blocks with the supplementary information cannot be combined in any sequence with the basic information BASE. Thus, with the scalable expansion of H.264/MPEG-4 AVC for example, the block T 0 , S 2 , B 0 cannot be decoded before block T 0 , S 1 , B 0 .
The video information is output by the encoder in accordance with a scalable expansion of Standard H.264/MPEG-4 AVC, described for example in
Heiko Schwarz, Detlev Marpe, and Thomas Wiegand: MCTF and Scalability Extension of H.264/AVC, Proc. PCS'04, San Francisco, Calif., USA, Dec. 15-17, 2004
in the form of NALUs (Network Abstraction Layer Units). The NALUs are logically combined to form the blocks of FIG. 1 , with each block being able to contain one or more NALUs. The blocks of FIG. 1 can for example involve the encoded data for a Group of Pictures (GOP).
Corresponding file formats are defined for storage of the encoded data, as described for example in MPEG-4 Part 15 AVC File Format, in
ISO/IEC 14496-15:2004, information technology—Coding of audio-visual objects—Part 15: Advanced Video Coding (AVC) file format, 2004.
This format defines that the bits of the images are stored directly in the file without start and stop codes, which are used as markings for detecting the start and the end of a packet for the transmission of the video information. An additional dataset, known as the hint track, contains information as to how the video information is packed for sending in RTP packet (RTP) Real-Time Transport Protocol) and can subsequently be sent. RTP is the protocol used for sending video information. Definitions of the so-called Random Access Recovery Points are contained in the stored video information which allow random access to the video information.
FIG. 2 shows the storage of the video information in accordance with the method. A first stored dataset MEDIA-STREAM exists, which contains the NALUs. The NALUs are symbolized by vertical bars within the sections of the dataset MEDIA-STREAM. Within the dataset MEDIA-STREAM the NALUs are sorted according to classes, so that logically associated NALUs belong to a class. Thus the first section of the dataset MEDIA-STREAM contains the NALUs of the BASE block of FIG. 1 . The second section contains the NALUs of block T 0 , S 0 , B 1 of FIG. 1 , the third section the NALUs of block T 1 , S 0 , B 1 of FIG. 1 , the fourth section the NALUs of block T 0 , S 1 , B 0 of FIG. 1 , the fifth section the NALUs of block T 0 , S 1 , B 1 of FIG. 1 and the sixth section the NALUs of block T 1 , S 1 , B 0 of FIG. 1 . Each block of FIG. 1 or each section of the dataset MEDIA-STREAM of FIG. 2 corresponds to a class. In the example described a class only contains the NALUs of a spatial, a temporal and an SNR scaling stage. Thus for example video information for different spatial resolution stages is not to be found in a class. Other distributions of NALUs into classes are also possible, as well as another sequence of the classes within the dataset MEDIA-STREAM.
The NALUs of a class are stored consecutively in the dataset MEDIA-STREAM, so that when the video information is sent via RTP the number of accesses to the dataset MEDIA-STREAM remains as small as possible. When the NALUs are sent via RTP, the NALUs of a class are preferably combined in an RTP packet provided the length of the RTP packet allows this.
As well as the dataset MEDIA-STREAM there exists a further dataset META-STREAM. The two datasets MEDIA-STREAM and META-STREAM are preferably stored as two separate files. The dataset META-STREAM contain metadata for the dataset MEDIA-STREAM and is thus used for description of the dataset MEDIA-STREAM. The dataset META-STREAM contains pointers to the contents of the dataset MEDIA-STREAM, so that the position within the dataset MEDIA-STREAM at which the NALUs of the different classes, identified by the specification of the variables T, S and B are stored, can be taken from the dataset META-STREAM. As shown in FIG. 2 reference is made to each individual class. Within the individual classes there can be references, not shown in FIG. 2 , to the individual NALUs of the respective class. Thus for example, when the position of the class T 0 , S 0 , B 1 is specified within the dataset META-STREAM it can be specified at which position within the dataset MEDIA-STREAM the three NALUs of this class are located in each case. In this way, using the dataset META-STREAM, the elements or NALUs of the dataset MEDIA-STREAM can be accessed hierarchically.
In particular it is not necessary, in order to find the NALUs of a specific class or one NALU of a specific class, to search through the dataset MEDIA-STREAM or read out its contents. Instead the describing dataset META-STREAM allows access to the individual classes.
As well as the dataset META-STREAM, further additional datasets can be used, which make it easier to handle dataset MEDIA-STREAM, symbolized in FIG. 2 as further dataset FURTHER META-STREAM. Alternatively the information described below of the additional dataset FURTHER META-STREAM can also be included in the dataset META-STREAM.
The storage of assignment specifications MAPPING-TABLE of the classes to larger groups, referred to below as layers, is advantageous. A first layer can include the blocks T 0 , S 1 , B 0 , T 1 , S 1 , B 0 , T 1 , S 0 , B 0 , T 0 , S 0 , B 1 , T 1 , S 0 , B 1 , T 0 , S 1 , B 1 and T 1 , S 1 , B 1 for example, a second layer of the blocks T 2 , S 0 , B 0 , T 2 , S 0 , B 1 , T 2 , S 1 , B 0 and T 2 , S 1 , B 1 , and a third layer of the blocks T 0 , S 2 , B 0 , T 0 , S 2 , B 1 , T 1 , S 2 , B 0 , T 1 , S 2 , B 1 , T 2 , S 2 , B 0 and T 2 , S 2 , B 1 . The layers should be constructed so that each layer in at least one scaling direction, i.e. in relation to at least one of the axes T, S or B, must contain a higher resolution stage than the next lower layer The NALUs of a layer can only be decoded, if the NALUs of the previous layer were decoded. If a mapping specification MAPPING-TABLE is stored between the classes or NALUs and the layers, a layer-by-layer transmission instead of a class-by-class transmission can be undertaken when the video information is sent. In a layer-by-layer RTP transmission all NALUs of a layer are preferably contained in one RTP packet, provided the size of the RTP packet allows this, whereas with a class-by-class transmission all NALUs of a class are contained in an RTP packet provided the size of the RTP packet allows this. If this is not possible because of the restricted size of the RTP packet, the NALUs of a layer or a class are divided up into a number of consecutive RTP packets.
The layer-by-layer transmission of the scalable video information has the advantage that the scaling operations in the network which perform the forwarding to the terminal, or also the operations in the terminal, are less complex. Thus it can be decided in a distributor with a yes/no decision as to whether the NALUs of the next-higher layer are to be forwarded to a specific terminal or not, or a terminal can use a yes/no decision to decide whether the NALUs of the next-higher layers are to be decoded or not. With class-by-class transmission on the other hand there are more degrees of freedom as regards the classes to be decoded or to be forwarded, thus either the class T 1 , S 1 , B 0 or the class T 2 , S 0 , B 0 could be forwarded or decoded after the class T 1 , S 0 , B 0 . This has the advantage of greater flexibility.
The conversion specification MAPPING-TABLE between the classes and layers of the video information is advantageously made up of information which is sent out by the receiver of the video information. Thus the receiver can communicate which quality levels of the video information it expects or needs or can process. The encoder uses these specifications to form an assignment of classes to layers, with only the assignments of those layers being stored which are useful for the receiver. Before the transmission the NALUs from the dataset MEDIA-STREAM can then be packed into RTP packets in accordance with the information of the dataset META-STREAM and the conversion specification MAPPING-TABLE and sent to the receiver in accordance with the latter's requirements.
A concrete example is considered below. The receiver indicates that it cannot display the resolution 4CIF. If 4CIF corresponds to the third line of the blocks of FIG. 1 , then at most the blocks of the first two lines are sent to the receiver. FIG. 3 shows an example of the structure of the assignment table MAPPING-TABLE stored in the dataflow FURTHER META-STREAM for this case of the receiver request: The basic information merely contains the block BASE, it makes up a separate layer, corresponding to the lowest layer. The first layer LAYER 1 includes the SNR updates of the basic information BASE (B=1) and the updates to the next temporal resolution (T=1). The second layer LAYER 2 contains all updates compared to the first layer LAYER 1 to the next spatial resolution (S=1). The third layer LAYER 3 contains all updates compared to the second layer LAYER 2 to the full temporal resolution (T=1).
Furthermore information STRATEGY can be stored in the dataset FURTHER META-STREAM about sensible scaling options. This includes for example which classes are to be transmitted to which types of receiver, which classes are to be sent under specific traffic conditions, which classes are to be sent for specific transmission modes, such as the low delay mode. In this way it can be stored that classes with a high spatial resolution are to be sent to mobile computers, whereas lower spatial resolutions are sufficient for mobile telephones because of their smaller displays. The information MAPPING-TABLE and STRATEGY can also be used in combination.
The information of the dataset FURTHER META-STREAM can be sent by the encoder into the communication network in order to be used there in the distribution of the video information to terminals. Thus for example the encoder of the NALUs can send all classes and additionally a conversion specification MAPPING-TABLE. When it receives this information a distribution device converts the class-by-class transmission into a layer-by-layer transmission and forwards the layers to a specific terminal. In this way a conversion can be undertaken of the scaling options at different points between a server and a terminal.
In accordance with the method, scalable data is stored according to a first order, in the concrete example according to classes, in a first dataset. Since under some circumstances a second order, referred to as layers in the concrete example, can prove more advantageous for a transmission of the scalable data, information is stored in another dataset which makes it possible to convert the first order into the second order This allows great flexibility in relation to the transmission of scalable data, a flexible adaptation to requirements in the network or to the options of the terminal is possible. The adaptation path is not defined by the storage of the data and the data can be scaled/adapted not only in the way predetermined by the first order. This flexibility can be maintained up to the point in time at which the data can be packed for transmission in packets, or by transmission of the mapping table, even forwarded to distributor stations.
A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004). | The following are saved as a first dataset in a first order: basic information and a plurality of elements containing information during the decoding process. Details about the position of the elements in the first dataset are saved as a second dataset. Information about the conversion of the order of the elements from the first order into a second order is also available. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to packages for cosmetic products; and more particularly, to such packages having an applicator which is utilized for application of the cosmetic product; and specifically, to such packages which include two wipers which act on the applicator.
2. Description of the Prior Art
Typical commercial mascara packages include a small elongated cylindrical bottle containing a quantity of mascara and a brush which includes a cap for the bottle. The cap also operates as a handle for the brush. The brush typically comprehends a stem extending from the interior of the cap which has a plastic portion and a twisted wire portion which supports the bristles. The twisted wire portion generally has a small diameter relative to the plastic portion. The bottle generally includes a wiper installed within the neck of the bottle. The wiper has a centrally located opening having a diameter of about the diameter of the larger plastic portion of the stem. The wiper is intended to remove all mascara from the stem and any excess mascara from the ends of the bristles.
Although such packages are relatively inexpensive to manufacture, they are generally messy to use. For example, a common problem experienced by users of current mascara packages is known as "tailing" wherein a tail of mascara is left on the distal end of the brush stem. Since the opening in the wiper is generally sized to the diameter of the plastic portion of the stem, the wiper does not engaged the "tail" of mascara which may extend from the distal end of the brush as it exits through the wiper. Thus, a small blob of mascara is left at the end of the brush. This small blob of mascara has a tendency to relocate on the skin about the eyes of the user. Many mascara users have learned to wipe the end of the brush on the mascara bottle above the wiper. Unfortunately, when the brush is reinserted into the package this blob is spread up the stem by the wiper, resulting in an even messier situation.
This problem has been recognized for some time and rather complex remedies have been proposed. For example, U.S. Pat. No. 2,990,834 issued to Amen on Jul. 4, 1961 discloses a valve element that is spring loaded against the end of the brush so that as the brush is retracted, the valve element is held securely against the trailing end of the brush. As the end of the brush exits the wiper, the valve element prevents the attachment of a "tail" so the brush stem has a clean tip. Unfortunately, the valve element and spring add considerable mechanical complexity and cost to the package.
Another disadvantage of typical commercial mascara packages is their inability to wipe mascara from the core of the bristle pattern. This also limits the sizes and shapes of bristle patterns which may advantageously be used with such packages. Since the opening in the wiper generally matches the diameter of the plastic portion of the stem, the core of the bristle pattern extending about the twisted wire is not wiped by the wiper. The mascara left near the bristle core tends to remain there during repeated removals and insertions of the brush from and into the container. The mascara near the core tends to dry out and may subsequently be deposited on the eyelashes of the user as dry chunks which can cause flaking and smudging.
U.S. Pat. No. 4,403,624 issued to Montgomery on Sep. 13, 1983 enables wiping near the core of the bristle pattern by enlarging the diameter of a portion of the stem which supports the bristles. An inner wiper having an opening with a diameter about the size of the diameter of the stem supporting some of the bristles provides most of the wiping action. An outer wiper having an opening significantly larger than the diameter of the largest stem portion helps prevent splattering of the mascara as the brush is withdrawn and provides some minimal wiping action. Unfortunately, this package does not solve the tailing problem. Furthermore, mascara can be driven up the stem, since mascara wiped from the inner wiper as the brush is reinserted has no other place to go and can readily pass through the large opening of the outer wiper.
U.S. Pat. No. 4,886,387 issued to Goldberg et al. on Dec. 12, 1989 discloses a mascara container having an upper wiper element near the open end of the mascara container and a lower wiper element located near the lower end of the container. The lower wiper element serves to divide the container into two chambers. The lower wiper has a relatively small opening to wipe the bristles near the core prior to charging the brush with mascara. Once the bristles are pulled through the lower wiper the brush is charged by swirling and/or pivoting the brush in order for the brush to contact the mascara which is somehow filled in a coaxial fashion within the container and about the brush. The upper wiper element removes any excess mascara from the ends of the bristles as the brush is removed from the package and wipes the surface of the supporting red clean as the rod is withdrawn. Here again a rather expensive and complex packaging system is disclosed. Furthermore, this package apparently does not deal with the tailing problem and the problem of mascara being driven up the stem.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention a cosmetic product package is provided which includes a container and a applicator. The container has a plurality of walls connected so as to house the cosmetic product. The container also includes an opening in one of the walls providing communication with the cosmetic product housed within the container. The applicator includes a stem having a means for grasping the applicator at the proximal end of the stem and a means for applying the cosmetic product at the distal end of the stem. The package further includes a dual wiper mechanism located within the opening of the container. The dual wiper mechanism includes a primary wiper element having an opening therein. The opening preferably has a diameter sufficiently small that no significant tail is left on the end of the stem as the applicator is removed from the container. Preferably the diameter of the opening in the primary wiper element is less than about the diameter of the distal end of the stem. A secondary outer wiper element having an opening therein is also part of the dual wiper mechanism. The secondary wiper provides wiping of the stem. Additionally, dual wiper mechanism includes a housing which locates the primary wiper element within the opening of the container and secondary wiper element within the opening of the container exteriorly of the primary wiper element and spaced from the primary wiper element forming a residual product reservoir between the primary wiper element and the secondary wiper element. The housing has a channel providing fluid communication from the residual product reservoir around the primary wiper element. The container may also include a separate discard reservoir and the housing may include a channel providing fluid communication between the residual product reservoir and the discard reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of preferred embodiments taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements and wherein;
FIG. 1 is a cross-sectional view of a preferred mascara package with the brush portion detached from the bottle portion;
FIG. 2 is an enlarged fragmentary cross-sectional view of the preferred mascara package in FIG. 1 illustrating the dual wiper mechanism;
FIG. 3 is an enlarged fragmentary cross-sectional view similar to FIG. 2 with brush portion attached to the bottle portion;
FIG. 4 is a cross-sectional view of the mascara package of FIG. 1 with the brush portion partially withdrawn from the bottle portion;
FIG. 5 is an enlarged fragmentary cross-sectional view of the mascara package of FIG. 1 with the brush portion partially withdrawn from the bottle;
FIG. 6 is an enlarged fragmentary cross-sectional view generally similar to that of FIG. 5 but having the brush portion further withdrawn from the bottle portion so that the bristles are within the dual wiper mechanism;
FIG. 7 is an enlarged cross-sectional view generally similar to that of FIG. 6 but having the cap portion still further withdrawn from the bottle portion so that the bristles are about to exit the dual wiper mechanism;
FIG. 8 is a cross-sectional view of the mascara package of FIG. 1 with the brush portion partially inserted into bottle portion;
FIG. 9 is an enlarged fragmentary cross-sectional view of a dual wiper mechanism of the mascara package in FIG. 1, with the bristles partially inserted through the dual wiper mechanism;
FIG. 10 is an enlarged fragmentary cross-sectional view generally similar to that of FIG. 9 but having the brush portion further inserted into the bottle portion with the stem partially inserted into the dual wiper mechanism;
FIG. 11 is an enlarged fragmentary cross-sectional view generally similar to that of FIG. 10 but having the brush portion still further into the bottle portion with the stem further inserted through the dual wiper mechanism;
FIG. 12 is a cross-sectional view similar to FIG. 1 of an alternative embodiment of a mascara package of the present invention with the brush portion partially inserted into the bottle portion;
FIG. 13 is an enlarged fragmentary cross-sectional view similar to FIG. 2 of the alternative embodiment of the mascara package in FIG. 12 illustrating the dual wiper mechanism;
FIG. 14 is an enlarged fragmentary cross-sectional view similar to FIG. 2 of a second alternative embodiment of a mascara package of the present invention; and
FIG. 15 is an enlarged fragmentary cross-sectional view similar to FIG. 2 of a third alternative embodiment of a mascara package of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In a preferred embodiment shown in FIG. 1, the present invention provides a cosmetic product package, generally designated 20. Although the terms "cosmetic product" and "mascara" are used throughout, this package may be advantageously used with a variety of products and this language is not meant to be limiting. The cosmetic product package 20 includes bottle portion 30 and brush portion 80. Brush portion 80 includes overcap 81 and stem 85. Overcap 81 is provided with internal threads 82. Stem 85 comprehends plastic portion 86, and twisted wire portion 92 which supports bristles 91. As in this embodiment, the diameter of twisted wire portion 92 is typically small relative to the diameter of plastic portion 86. Twisted wire portion 92 is permanently fastened to plastic stem portion 86. Bristles 91 extend from twisted wire portion 92 of stem 85. Stem 85 is cantilevered from and integrally molded with plug 87 which is permanently fastened to overcap 81 by adhesive, snap-fit or other suitable means.
Bottle portion 30 includes bottle 31 and dual wiper mechanism 40. Bottle 31 is generally cylindrical in form and has a closed end 32 and an open end opposite thereto at neck 33. Neck 33 is provided with external threads 34 which are engageable with internal threads 82 on overcap 81 to releasably secure brush portion 80 to bottle 31, as seen in FIG. 3. The interior of bottle 31 forms primary product reservoir 35 for housing the cosmetic product.
Referring to FIG. 2, the dual wiper mechanism 40 includes housing 42, primary wiper 70, and primary wiper retainer 60. Secondary wiper 41 extends from, and is integrally molded with housing 42. Secondary wiper 41 includes a centrally located opening 44 having a diameter about the diameter of the plastic portion 86 of stem 85. Housing 42 includes a inwardly extending cylindrical portion 43 below the secondary wiper 41 which terminates in an annular bead 50. The cylindrical portion 43 includes several radially spaced slots 47.
Primary wiper 70 includes centrally located opening 71. The diameter of opening 71 of this embodiment is about equal to the diameter of twisted wire portion 92 of the stem 85. Primary wiper 70 is made of a resilient material such as a silicone elastomer. Preferably the material of primary wiper 70 has a hardness of between about 40 Shore A and about 100 Shore A.
Primary wiper retainer 60 is a generally cylindrical unitary molded part including inner flange 61 which has an outwardly directed annular bead 66. In addition, primary wiper retainer 60 includes several radial slots 65 spaced to match slots 47 of cylindrical portion 43. Lock bead 64 of primary wiper retainer 60 snaps into groove 48 of housing 42, thereby fastening primary wiper retainer 60 onto housing 42. Upon fastening primary wiper retainer 60 to housing 42, annular bead 50 of cylindrical portion 43 of housing 42 and annular bead 66 of inner flange 61 of wiper retainer 60 confine thickened peripheral annular portion 72 of the primary wiper 70 to secure the periphery of primary wiper 70.
Once fastened, the inner surface of secondary wiper 41, the outer surface of primary wiper 70, and the interior of cylindrical portion 43 form residual product reservoir 52. Primary wiper retainer 60 is interrupted by slots 65 which align with slots 47 of cylindrical portion 43 to provide channels which communicate between residual mascara reservoir 52 and primary product reservoir 35.
Once assembled, dual wiper mechanism 40 is permanently inserted into neck 33 until flange 46 of housing 42 engages the face of neck 33 and limits the introduction of secondary wiper 41 into neck 33. Dual wiper mechanism 40 may be permanently held in place, for example, by utilizing a friction fit, a snap fit and/or adhesive between the outer surface of housing 42 and the inner surface of neck 33.
Referring to FIG. 3, brush portion 80 is secured to bottle portion 30 by means of screws threads 82 and 34, respectively. Plastic stem portion 86 is shown penetrating opening 44 in secondary wiper 41 and opening 71 in primary wiper 70. Primary wiper 70 is shown deflected inwardly and elastically distended about plastic stem portion 86. This is due to the fact that opening 71 in primary wiper 70 is smaller in diameter than the diameter of the plastic portion 86 of stem 85. Bead 89 of plug 87 engages the outer surface of flange 46, thereby further sealing cosmetic product package 20.
Referring to FIG. 4 and FIG. 5, brush portion 80 is being withdrawn from bottle portion 30 in the direction indicated by the arrow. Primary wiper 70 is shown deflected outwardly in response to the outward movement of stem 85. Mascara (not shown) in primary product reservoir 35 that adheres to outgoing stem 85 is wiped clean by primary wiper 70. Any residual mascara that may have been in residual product reservoir 52 is wiped by secondary wiper 41. The channels formed by slots 47 and 65 provide an outlet for residual mascara retained in residual product reservoir 52 in order to accommodate the displacement of volume within residual product reservoir 52 as primary wiper 70 is deflected, thereby reducing the volume of residual product reservoir 52.
Referring to FIG. 6, the package 20 is illustrated with twisted wire 92 and bristles 91 within dual wiper mechanism 40. The primary purpose of the dual wiper mechanism 40 is to ensure an appropriate quantity of mascara is applied to the bristles 91 of the brush portion 80. In addition to providing this basic requirement, the dual wiper mechanism 40 further provides a clean stem 85 and virtually no tail on the brush portion 80. Excess mascara (not shown) from primary reservoir 35 is squeegeed from bristles 91 by primary wiper 70. Little additional wiping action occurs at secondary wiper 41.
Referring to FIG. 7, the package 20 is illustrated with the brush portion 80 about to exit primary wiper 70. The small opening 71 of primary wiper 70, as it approaches its relaxed condition, cause primary wiper 70 to close about the trailing end of brush portion 80, thereby removing virtually all the tailing mascara that tends to adhere to the outgoing brush portion 80 end. Thus, the diameter of the opening 71 in the primary wiper 70 is sufficiently small that no significant tail of mascara remains on the stem 85 as it is removed from the primary wiper 70. A tail is "significant" if it falls off brush portion 80, or otherwise negatively contacts the consumer during the normal process of applying mascara. Preferably, the diameter of opening 71 is about the same or less than the diameter of twisted wire 92 (i.e., distal end of stem 85).
Furthermore, dual wiper mechanism 40 of the present invention enables the use of non-standard brush shapes. For example, bristles 91 of this embodiment extend radially in all directions from twisted wire portion 92 of stem 85 so that the bristles 91, in aggregate, provide a circular cross-section. The diameter of the cross-section created by bristles 91 is about equal to the diameter of plastic portion 86 of stem 92. This diameter is significantly smaller than typical mascara packages, allowing greater control during application. Another example, illustrated in FIGS. 14 and 15, has bristles 291 and 391, respectively, which extend mostly in one direction while the opposing side of the supporting twisted wire 292 and 392, respectively, is void of all bristles. Other variations (not seen) of brush design, such as a brush having bristles extending in four directions only (i.e., such that the aggregate bristle cross-section forms an "X") are practical with the dual wiper mechanism 40 of the present invention.
Referring to FIGS. 8 and 9, subsequent to applying mascara to the eyelashes using brush portion 80, the user of mascara package 20 reinserts stem 85 of brush portion 80 back into bottle portion 30, either in preparation for closure and storage or in preparation for further mascara application. Although bristles 91 of brush portion 80 may encounter some minor wiping action as bristles 91 pass through opening 44 of secondary wiper 41, the smaller opening 71 in primary wiper 70 effects considerably more constriction and thus, wiping of bristles 91 of brush portion 80. In fact, the shape and size of secondary wiper 41 are preferably such that virtually no significant wiping action occurs upon reinsertion of the bristles 91 and stem 85 of brush portion 90. Thus, mascara will not build up on the stem 85, outboard of the secondary wiper 41. While the constricting effect of primary wiper 70 on the outgoing bristles 91 and stem 85 of brush portion 80 during withdrawal in preparation for use causes excess product to be squeegeed from bristles 91 and stem 85 of brush portion 80 on the inboard side of primary wiper 70, the reintroduction of bristles 91 and stem 85 of brush portion 80 back into bottle portion 30 causes primary wiper 70 to squeegee residual mascara from bristles 91 and stem 85 of brush portion 80 on the outboard side of primary wiper 70. This residual mascara accumulates in residual product reservoir 52 as the length of the stem 85 of brush portion 80 passes through primary wiper 70.
Referring to FIG. 10, most of bristles 91 of brush portion 80 are shown as having passed through primary wiper 70. The distal end of plastic portion 86 of stem 85 is shown having just entered opening 44 of secondary wiper 41. Opening 44 of secondary wiper 41 seals about the shaft of plastic portion 86 of stem 85. Further introduction of plastic portion 86 of stem 85 into residual product reservoir 52 causes the accumulated residual mascara to be displaced by the stem 85 and forced through the channels formed by slots 47 and 65 back into primary product reservoir 35.
FIG. 11 is an enlarged cross-sectional view similar to FIG. 10 but having stem 85 still further penetrating dual wiper mechanism 40 such that the leading end of plastic portion 86 of stem 85 is seen having just passed through opening 71 in primary wiper 70. Primary wiper 70 is deflected inwardly and stretched to accommodate the diameter of plastic portion 86 of stem 85. From the condition seen in FIG. 11, brush portion 80 will be further inserted into bottle portion 30 by the user to either recharge bristles 91 of brush portion 80 with additional mascara or to seal mascara package 20 in preparation for storage.
Referring to FIG. 12, an alternative embodiment of the present invention is provided in which cosmetic product package 120 comprises bottle portion 130 and brush portion 180. Brush portion 180 is virtually identical to brush portion 80 of the embodiment of FIGS. 1-11, previously described.
Bottle portion 130 includes inner bottle 131, outer bottle 197, and dual wiper mechanism 140. Inner bottle 131 and outer bottle 197 are coaxial and generally cylindrical in form and both are closed at one end having a common end plate 132. Inner bottle 131 has an open end opposite end plate 132 at neck 133. Neck 133 is provided with external threads 134 which are engageable with internal threads 182 on overcap 181 to releasably secure brush portion 180 to bottle portion 130. The interior of inner bottle 131 provides primary product reservoir 135. The space between the exterior of inner bottle 131 and the interior of outer bottle 197 generally defines discard product reservoir 195. Radial partitions 139 project inwardly from the interior of outer bottle 197 toward and engage the outer surface of inner bottle 131 to edges 129.
Referring to FIG. 13, wiper mechanism 140 includes housing 142, primary wiper 170, and primary wiper retainer 160. Housing 142 includes secondary wiper 141, inwardly extending cylindrical portion 143 which terminates in annular bead 150 and several radially spaced slots 147, similar to the previously described housing 42. In addition, housing 142 includes groove 138 which functions as a vent channel.
Primary wiper retainer 160 is generally similar to primary wiper retainer 60, including outwardly directed bead 166, lock bead 164 and radial slots 165. In addition, primary wiper retainer 160 includes an elongated cylindrical portion below primary wiper 170 which serves to bound inner bottle 131. Primary wiper retainer 160 also includes groove 169 which in combination with groove 138 functions as a vent channel for discard reservoir 195.
The operation of dual wiper mechanism 140 of mascara package 120 is generally similar to that described for dual wiper mechanism 40 of mascara package 20 with the important distinction that the residual mascara that accumulates in residual product reservoir 152 as brush portion 180 is reinserted into dual wiper mechanism 140 is diverted via the channel formed by the combination of radial slots 165 and 147 into discard product reservoir 195. Discard product reservoir 195 is isolated from primary product reservoir 135 so that mascara diverted into discard reservoir 195 is not available for further dispensing and application. As discard mascara flows into discard reservoir 195, air in discard reservoir 195 is displaced through vent channel created by grooves 169 and 138.
Referring to FIGS. 14 and 15, dual wiper mechanisms 240 and 340, respectively, include means for doctoring less product from the bristles 291 and 391, respectively as the brush portion 280 and 380, respectively is removed from the package 220 and 320, respectively than when the brush portion 280 and 380, respectively is returned to the package 220 and 320, respectively. Such a means may be advantageous, for example, with an embodiment including a discard product reservoir 195, such as that seen in FIGS. 12 and 13. As seen in FIG. 14, such a means is provided by elongating the annular bead portion 266 of primary wiper retainer 260 such that additional rigidity is provided to the primary wiper 270 as it is deformed toward the interior of the bottle 231. Thus, the primary wiper 270 deflects more readily as the stem 285 of brush portion 280 is removed from the bottle 231 than when the stem 285 of brush portion 280 is inserted into the bottle 231; thereby doctoring the bristles 291 more upon insertion of the stem 285 of brush portion 280 than upon removal.
As seen in FIG. 15, an alternative means is illustrated wherein the primary wiper 370 includes a conically shaped interior surface such that the primary wiper 370 resists deflection toward the interior of the bottle 331. Thus, the primary wiper 370 deflects more readily as the stem 385 of brush portion 380 is removed from the bottle 331 than when the stem 385 of brush portion 380 is inserted into the bottle 331; thereby doctoring the bristles 391 more upon insertion of the stem 385 brush portion 380 than above removal.
While particular embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the present invention. Accordingly, the present invention comprises all embodiments within the scope of the appended claims. | A cosmetic product package, particularly a mascara package, including a dual wiper mechanism which virtually eliminates the messiness problems of typical mascara applicators. The dual wiper mechanism has a resilient inner wiper and a resilient outer wiper spaced apart from one another within a supporting structure forming a residual mascara chamber therebetween. The inner wiper has a relatively small opening which provides most of the doctoring of the bristles. The outer wiper has a larger opening which primarily doctors the stem. Mascara which collects in the residual chamber flows through conduits around the inner wiper back into the primary reservoir, or alternatively to a discard reservoir. A mechanism to doctor more mascara from the brush upon insertion than upon removal of the brush may also be provided. | 0 |
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